Hi. Just got a new PMD from Dipaco which did not solve my throttle issues but did provide a noticably quieter/smoother/better ride. I previously had the FSD cooler mounted on the Manifold, but from everyone's helpful suggestions figured it was time to put it on the bumper.

Because I already had the finned heat sink, I decided to just re-use it, and because I'm on the road and have limited tools here I did the best I could with mounting it.

Would love some feedback, or if you're planning on doing it yourself, here's some pictures of what I did.

http://www.ilipsisdesign.com/beano/IMG_3689.jpg
The old one (which the previous owner wrote "new" on) attached to heat sink, and the new Dipaco on the left. I tried to remove this from the truck after driving and it was too hot to touch - so I'm glad I moved it.

http://www.ilipsisdesign.com/beano/IMG_3690.jpg
This is what the old one looked like when I popped it off. There was a distinct smell of burnt plastic coming from it, so it's probably a damn good thing I moved it.


http://www.ilipsisdesign.com/beano/IMG_3691.jpg
My heat sink after scraping it down with a razor blade and then cleaning it with nail polish remover (my fiancee's, I swear!)


http://www.ilipsisdesign.com/beano/IMG_3692.jpg
A photo of the Heat Sink compound I used. made a nice thin layer using the razor blade.


http://www.ilipsisdesign.com/beano/IMG_3694.jpg
The new FSD attached to the heat sink with the included screws, then I made that big grey weatherstrip around it to be sure it's sealed.

http://www.ilipsisdesign.com/beano/IMG_3699.jpg
I attached the heat sink to the bottom part of the bumper (lower than I would have liked) by removing one of the screws that holds the plastic piece on the bottom of the bumper, then using a nut/bold and 2 washers to bolt the sink onto the actual metal of the bumper. My heat sink has basically a tab that used to attach it to the Manifold, this tab is now wedged between the bumper and that plastic. Sad thing is that I could only line up one bolt hole. I'll definitely build an aluminum mount for this when I get home. The Kennedy 4' Extension Harness I used can be seen dangling on the left. pre hook up.

http://www.ilipsisdesign.com/beano/IMG_3697.jpg
Here's the top view of where I mounted it. look how much air it's going to get over those fins! yay! and thanks to whoever it was that told me that the fins MUST point straight up and down... makes a lot of sense, heat rises!

http://www.ilipsisdesign.com/beano/IMG_3703.jpg
In order to mount the cooler in this location, I had to remove the plastic piece that was inside the bumper (looks like it's meant to hold fog lights or something) but I re-used it by zip-tying it to the frame to give the new location a little protection against rocks, etc. Not a permanent solution, but some help.

http://www.ilipsisdesign.com/beano/IMG_3705.jpg
Here's how it looks from below, with that plastic piece protecting the bottom of the FSD.

well, that's all folks, what say you?

Again, this did not fix the problem I'm having, which, if you feel like helping with, can be read all about HERE:
http://www.dieselplace.com/forum/showthread.php?t=184515

The plastic piece in your bumper nostril was there to direct airflow to the radiator.

doh!

think it'll be ok? mine was cut out around the nostrils anyway, so it didn't seem like it would be directing too much of anything. I'll watch temps carefully!

You could have mounted that heat sink inverted- from the way you have it.
If you are not having overheat issues with that nostril cowling removed it should probably be okay.

The only issue with mounting on the bumper is if you hit something lightly with the bumper in the middle. The bumper will bend easily and maybe screw up your installation- making a driveable post accident truck, undriveable.

I recommend getting a piece of pre- drilled angle brackett from your local building supply and bolting between the two frame rails in the front- behind an back from the bumper. It is high enough to avoid road trash and far enough back to be protected in a crash.