Adding Intercooler - how did everyone do it
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Senior User
Joined: May 2005
Posts: 157
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From: shiloh, kentucky
Adding Intercooler - how did everyone do it
I have PMS and taking small steps. My current step is adding an intercooler. I have the cooler, a 6.0, and a spyder Y pipe. Next is the pipes and hose connectors. I am curious how/what everyone has done. DIY and if so, did you bend your own pipe or buy some already bent. Or did you purchase a kit from someplace, and if so part# and who. Other options?
thanks for any input
thanks for any input
Post Fiend
Joined: Apr 2004
Posts: 12,835
Likes: 3
From: Silver Lake Dunes, MI
First thing you should do is trade me your 6.0 IC for my 7.3. The 6.0 cooler will be way too hard to fit in there! I'll save you the trouble and trade you! LOL
Ok I guess you can keep it! For my pipes I had a set of 7.3 superduty pipes and another driverside 7.3 pipe. plus I used about 4 inch of 3" exhuast pipe that was laying around.
For the drivers side pipe I use the SD 7.3 driverside pipe but flipped it end for end and added a few inches to the turbo end. Then the passenger side pipe is the extra SD 7.3 driverside pipe that is al hatched up. the two 90* bends are from the extra driverside pipe. the IC end shortened then the turbo end of my pipe is from the Passenger side SD 7.3 pipe with the turbo end shortened. Its hard to explain. If I get a chance this afternoon I will take this pic and disect it for you with a description so you can see exactly what I mean.
PS- I have a 3 inch pipe bender and pipe on hand but its not mandrel bends so I elected the cut and paste method. Once i get my pipes ground smooth and painted (still not done!!) I will be very happy with these pipes.
Ok I guess you can keep it! For my pipes I had a set of 7.3 superduty pipes and another driverside 7.3 pipe. plus I used about 4 inch of 3" exhuast pipe that was laying around.
For the drivers side pipe I use the SD 7.3 driverside pipe but flipped it end for end and added a few inches to the turbo end. Then the passenger side pipe is the extra SD 7.3 driverside pipe that is al hatched up. the two 90* bends are from the extra driverside pipe. the IC end shortened then the turbo end of my pipe is from the Passenger side SD 7.3 pipe with the turbo end shortened. Its hard to explain. If I get a chance this afternoon I will take this pic and disect it for you with a description so you can see exactly what I mean.
PS- I have a 3 inch pipe bender and pipe on hand but its not mandrel bends so I elected the cut and paste method. Once i get my pipes ground smooth and painted (still not done!!) I will be very happy with these pipes.
Elder User
Joined: Oct 2004
Posts: 782
Likes: 1
From: Olympia, WA
Good info, thanks for sharing Tim. What about mounting the IC itself, looks like everyone puts id down about as low as it will go with lower mounts just above the frame rails. Any tips on mounting, stuff you learned or would do differently next time? Are you still running MAP and boost off a T/bung in the turbo exit side?
Post Fiend
Joined: Apr 2004
Posts: 12,835
Likes: 3
From: Silver Lake Dunes, MI
As for mounting the IC you want to go as high as you possibly can. I bent my hood release around to clear a bit higher. As it is now the lower mount is about 2 inches above the top of the frame rail.
My two regrets to my install were first of not getting a 6.0 cooler. second which hasn't caused any problems but I wish I had spent more time and built a bracket for the lower mounts that would attach to the core support rather than the frame.
And yes I am still running the MAP line and boost gauge off the hot side at the turbo outlet rather than the stock location on the cold side on the intake plenum.
My two regrets to my install were first of not getting a 6.0 cooler. second which hasn't caused any problems but I wish I had spent more time and built a bracket for the lower mounts that would attach to the core support rather than the frame.
And yes I am still running the MAP line and boost gauge off the hot side at the turbo outlet rather than the stock location on the cold side on the intake plenum.
Elder User
Joined: Oct 2004
Posts: 782
Likes: 1
From: Olympia, WA
Thanks Tim. Why mount the IC high, airflow or other clearance issues? One example writeup said raising it reduces the amount of cutting on the core support, especially the thick sections. I'm going to be starting on this in the next couple weeks, Dad bought me a Banks spider for Xmas, got all I need now.
Post Fiend
Joined: Apr 2004
Posts: 12,835
Likes: 3
From: Silver Lake Dunes, MI
I mounted the IC as far up as possible for both airflow and clearance down low. Especially with the 6.0 cooler if you don't get high enough the IC will hange below the bumper. I wanted mine protected from brush and small animals. As well as being higher enough to not cut the double thick section of the core support.
Here are some disected pics of my IC pipes. They are a bit sloppy but I am still learning to work with Photoshop.
By same bends I mean that the pipe on the right was built from a pipe just like the one on the left
Here are some disected pics of my IC pipes. They are a bit sloppy but I am still learning to work with Photoshop.
By same bends I mean that the pipe on the right was built from a pipe just like the one on the left
Post Fiend
Joined: Mar 2007
Posts: 9,010
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From: Johnson City, TN.
Tim I was looking at your brackets and I understand the top one. And the bottom one is pretty straight forward but I don't understand what you mean by cutting the core support?
Also I have somee strips of thick rubber that is about 1' X 1.5" do you think I can use that in the lower brackets. I was thinking of fitting it up in the lower bracket and affixing it to a piece of metal. What do you think of this idea?
Also I have somee strips of thick rubber that is about 1' X 1.5" do you think I can use that in the lower brackets. I was thinking of fitting it up in the lower bracket and affixing it to a piece of metal. What do you think of this idea?
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Post Fiend
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From: Johnson City, TN.
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Post Fiend
Joined: Apr 2004
Posts: 12,835
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From: Silver Lake Dunes, MI
Thanks Neal for the offer on the rubber but I think I am all set
This is a pic of the holes needed to be cut in the core support. The area just below with the curve that goes down and to the left is double thick and a major supporting member
This is a pic of the holes needed to be cut in the core support. The area just below with the curve that goes down and to the left is double thick and a major supporting member
Post Fiend
Joined: Mar 2007
Posts: 9,010
Likes: 5
From: Johnson City, TN.
OOOooohhhhh. No9w I see. The word "core" threw me off. I thought you were having to modify the cooler itself. Thanx.
Anyway enough of the airheadedness. Do you think that is a good idea using the rubber. Or do you like the mount directly to the frame like you did better?
Anyway enough of the airheadedness. Do you think that is a good idea using the rubber. Or do you like the mount directly to the frame like you did better?
Post Fiend
Joined: Apr 2004
Posts: 12,835
Likes: 3
From: Silver Lake Dunes, MI
Originally Posted by RÖENTGEEP
Tim, did you modified the supports of the condenser to move it rearward? and how did you support the tranny cooler?
