Intercooler install
 

Been a few years in the making. Bought the parts about 2 years ago, installed the front mount heat exchanger about a year ago, just now getting to the plumbing and Spyder install.

One thing that I did not see mentioned in all the things I have read online was that the vacuum ports and air temp sensor hole would have to be shaved and plugged. I got a 3/8" plug for the air temp sensor and removed the vacuum line fittings and drilled and tapped for 1/8" pipe plugs.

So did the early 99 spyder and a 2000ish 7.3 heat exchanger. I got the piping and everything from the 2000 and decided to use the stock Ford stuff as much as I could.

I finished mocking up the tubing tonight and used parts of the Superduty tubes to help with the fabrication. Didn't take much pipe at all and now I am left with a bunch of extra 3" tubing but I think it came out pretty decent.

Will finish welding the tubing tomorrow and hopefully get the thing running again! Blue painters tape should hold 20psi of boost right? :-X06


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That looks really good! I would be really interested to hear exactly what you added to the SD pipes to make them work for this application. I picked up a set of pipes and a spyder a couple weeks ago for this install at some point. My trouble is that the pipes I found were aluminum. I'm not above scrapping them completely and building my own plumbing, but if the modifications to the pipes aren't that bad, I may just buy some tubing and bends and get it all TIG welded up.

Yeah I cut all of this using a hand hacksaw and some sand paper on a table and a hose clamp, LOL. Anyone should be able to make these it just takes some patience. I will get some pictures of the pipes when I have them out for welding later today. Basicallly the only thing left that is SD pipe is the two top parts pictured and the lower parts that connect to the silicone couplings. The ford pipes have a nice grove around them that kind of locks into the coupler so I wanted to keep that.

Definitly want to see more pics of the pipes. I also have a set of aluminum pipes that need to be modified.

Just finished the cold side pipe. The part that connects to the spyder is the SD pipe. I cut it where you see the first peice of tape in the pictures above. I then cut the grooved end off the left over part and welded it to the part that connects to the I/C. Used two 90* 3" aluminum bends.

Going to head out and finish the other side after lunch!

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stock intake still!!!?

Yup, haven't made that step yet, LOL

All done, might have to add on some brackets to keep the pipes in place but will see how it works out once I get it fired up.

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I have seen somewhere, a bracket attached to one of the alternator bolts to hold the pipe

Looks good I'm jelous of your passenger side pipe

Those look great. Too bad you didn't get measurements on where the cuts where and how much pipe was used and reduced. Would have helped the next guy to go this route.

Those look really good! Nicely done!

If I end up making a set of these pipes, measurements and pictures will be posted. That's a ways down the road though, I'm afraid.

Wish I was setup to weld aluminum

yea! when i bought my tig i thought i didnt need to do any alluminum work..yea,should have done the ac tig:-X19

I found my pipes to be an aluminized steel and I was able to weld mine with a MIG. I really like how your passenger pipe looks! Great job, looks factory!