1997 7.3 with 143,000. I'm not gonna be pushing to much hp/tq at all. I'll probably run it on the 100hp -140hp setting a hand full of times, and I only do a moderate amount of towing.

I'm trying to avoid that $1,100+ price tag while maintaining the longevity of my truck.

Here's a list of what I'll be running in a couple weeks.
1: Riffraff Diesel Triple Gauge Pillar Kit for Ford 7.3L 99-03 (wrong year, but you get the point.)
2: Bosch 7.3L Powerstroke 17º HPOP 96-97 Ford - HP005X
3: Riffraff Diesel Hutch In-Tank Fuel Mod Kit - Riffraff Diesel Performance
4: TS Performance 6 Position Chip w/ Tunes (possibly hydra, but custom tunes either way.)
5: MBRP 4" Turbo Back Stainless T409 Exhaust for Ford 7.3L (94-97)
6: S&B OBS Powerstroke Cold Air Intake Kit - Dry
7: Riffraff Diesel Billet Compressor Wheel 94-03 (RDP170293)
8: https://www.xtremediesel.com/ats-303...tor-valve-body
9: https://www.xtremediesel.com/bd-powe...ansmission-pan

All in all, it's a pretty simple setup.

 

I'm also "light-footed". I don't get in a hurry very often, at all.

 

I really like the Hydra and the Derale pan.

PHP Hydra Chip (PHP-HYDRA)

Derale Transmission Pan Coolers - 14208

 

I run a used TS chip with Gearhead tunes. Hydra is a better platform but costs more. I am pleased for how little I am into my setup.

Diamond Eye exhausts work just as well and cost less. Check them out. Deals are coming soon because of Thanksgiving weekend.

Make sure uppipes are not leaking!

 

Any opinions on when to add an itntercooler? Also, in theory, if I added a larger turbo (nothing much larger than stock.), wouldn't it help lower EGT's also? So, instead of spending $1'400 on an intercooler, I could spend it on something that will also increase power while continuing to move air. Keep in mind -- I'm talking out of my *** because, at best, I could be considered a hobbyist "mechanic'.

 

Drive how you do with an EGT gauge, then decide on IC.

 

As for your IC question IMHO I would do it regardless if you tow or not, its a safe assurance and also a key factor in engine reliability, remember the Super Duty's came with one, and if you plan on adding a hotter tune I guarantee your EGT will run hotter especially a WOT and while going up hill or towing something.

 

Any opinions on my turbo question? Would it just make it run hotter, or help out a bit?

 

Theres only so much a stock turbo do with a billet wheel. Yes a billet wheel can help reduce EGT's but dont expect a whole lot. And if your asking if the engine itself will run hotter then no Ford blessed us with very efficient cooling systems in our trucks.

 

Diesels work the opposite from gas engines as far as air flow. A gas engine burns lean and runs hotter with more air and a Diesel runs cooler, so yes, a "bigger" turbo should result in lower EGT's. The other side of this is that more the intake air gets compressed by the turbo, the more it gets heated. There's a point with a higher performance turbo where even though there's more air flow it is real hot air and results in higher EGT's. Not sure if there's anyway to know in advance what the EGT results will be just have to try it. No experience with it but the KCTP38R turbo is getting good reviews on another recent thread. Not exactly cheap though.

Note that my own turbo is stock with the exception of a 360 degree thrust bearing so I'm just passing on what I think I've learned and it may be subject to correction which it will no doubt be if I'm wrong...

 

With a stock setup as far as injectors no ic needed.
To that end you never have to have one except to keep egt in check you will have to back off the fuel further than with for the same amount of fuel.

This whole debate comes down to fuel vs air and having the proper amount of both.
Personally when my junk used to drive if I could keep revs up and turbo working egt was not an issue. If I got under the turbo then I was done.
Also gear ratio and tire size play into this along with load weight and type of shape you are pulling.

In my opinion only very stock trucks do not need an ic. Tunes,exh,intake,efuel I classify in the very stock arena. Once you do injectors and much pulse width then throw a lack of ic out the window.