Alright who has an intercooler? What brand? Any pictures? Did you install it yourself, if not then who? Are you satisified with the results? And finally what was the cost?

I would just like to know before I buy one.

Thanks,

The choice is a spear co kit for ~$1500 or fitting a PS or cummins or duramax IC or other yourself. I have three ebay ones so far for under $100 for all.

Lots of opinion's:exactly: here on intercoolers. Some spent the big bucks and got the kit, others built their own, the fun way, and some of us just ain't gone there yet.

I will be starting an install of a Dmax IC in the next couple of weeks I just got my welder filled with argon and will start doing the nec. mods on the IC to fit around the radiator. (need to cut one end and extend the width about 1-2"). I hope to have it in over the next month.

But having trans problems in wifes Toyota Sienna that I have to look into first. Anyone know about an extended warranty on Sianna trans (2000)? I found a TSB about it on the NHTSA website but no record of it on ALLDATA.

I will take lots of pics and keep everyone up to date with all mods to install IC for those interested.

It seems like everybody and their brother is going to custom make/install there own intercooler.

How many people have actually done it?


Initial layout on the kits are expensive.

Once installed...

Priceless.

I've done it.

Bought a used Spearco off of Ebay, a couple 2 1/2" U-bends, 90deg and 45deg cast aluminum elbows also off Ebay, a hose and clamp kit again off ebay, and a chunk of aluminized 2 1/2" exhaust pipe from a local shop.

My intercooler and all the plumbing appear to be very similar to the Spearco kit that's offered by some venders.

Results? Well, it's not gonna make a hotrod out of your truck. Normal driving isn't affected much. But I did notice I could really pull hills when towing a trailer, didn't slow way down like I did before the intercooler. I've had it on for about a year now and haven't had to do a thing to it.

I don't have any pics of my install but I hope to get some taken in the next week or so and if I can figure out how to post them on here I'll do it.

Hey all!!
New to the forum here.
My brother has a GMC Syclone. He removed his factory water-air intercooler for a front mount air-air. Being budget minded, I'm gonna try to make his old water-air work on my 96 6.5TD. I should be able to get it to work by modifying the upper intake a bit. Any thoughts on this?? I know it's not as effective as an air-air, but I gotta make do with what I've got.
I'll let you all know how it goes when I undertake this project.:grd:

you have the better of the 2 if you hook up the water part of the intercooler! sounds like you got the hard part done if you have the IC already. good luck in your install!!

i just yesterday received my 1' x 2' x 3" IC......damn nice if i say! i cant wait to get it installed this week....ill post up pics later

HEY TL, Got my stuff today, thanks

where you get your IC from ?

you have the better of the 2 if you hook up the water part of the intercooler! sounds like you got the hard part done if you have the IC already. good luck in your install!!Thanks!
I have 2 "rads" for cooling the intercoolers coolant. They're about the size of a trans cooler, so I'll probably run both. I also have an electric pump for circulating the coolant. I'll probly just wire it direct to the ignition so it comes on with the key.
I'll make sure I take some pics and put them up here too.

Here's what I'm replacing my GM-4 with. It should push more air with less heat to cool down.

WOW Looks about the size of a small gas engine LOL

It's the powerstroke garret, M-25 A/R60

How will you retrofit it?????

One of these:
It will fit, bolt it up.
make a transition that goes between the turbo and exhaust, bolt it up.
cut the stock flange off the exhaust manifold, make a new flange, weld it on the exhaust, bolt it up.

The turbo pictured above appears to be a wastegated turbo, not a 95. The 95 did not have a wastegate. The fins appear to be "sand-blasted". Common problem on Ford turbos. The air filter system sucks on those Powerstrokes. Dirt ingestion erodes the leading edge of the compressor wheel. Banks offers improved compressor wheels.
Check out (http://www..com)http://www.dieselinnovations.com/ford_diesel/7.3/ford_73_induction.htm
for install parts.

Need to check wheel before install QM.

The early '90s PS was mech inj - that wastegate is operated off Boost pressure, and at A/R 60, that turbo is probably less flo than the GM-8.

Being a Garrett, it is upgradeable, as DieselPro suggests.

I was just reading through that site and I've seen some of the same upgrades on the auction site for resale. There's an a/r 1.25 exhaust housing but it costs 9x more than this turbo cost me. I'll put a spring boost controller on it, like a reverse TM.

That is a spring controller cannister, with Boost pressure overcoming spring-pressure to open the WG.

Put a small air compressor regulator - say, 0-25psi - in that rubber line to manually regulate Boost pressure to whatever detonation value you choose.

You know - for when you're pushing the envelope...........

Sorry guys the question was "What intercooler are you using", not what turbo are you using. I am interested in innercoolers not turbos, my stock turbo is plenty capable, but I have no intercooler. I think the thread will have better responces/information if you stick to the subject.

Thanks,

The GM-x is 70% inefficeint above 10 psi or 30% efficeint if your an optimist.
It's valid to the question of intercooling in that how high IAT's climb is a direct result of turbo efficeincy or lack thereof. Intercooling regains some of the efficeincy lost from the compression heat of the turbo. About 30% overall.

That means if you intercool a gm-8 you gain up to 60% efficeincy above 10 psi. With a 60% efficeint turbo you'd gain 90% of your potential efficeincy. This is why grape is matching the perfect turbo (in his estimation) for his truck and IC, just a matter of efficeincy.

Hey, QM, do you have a compressor map that you're reading those numbers from? I'm pretty sure you don't, because those numbers are bogus. For another thing, you didn't specify what engine operating speed your 10 psi boost pressure was achieved at.

According to the map, that compressor can make 26 psi cdp at 2200 engine rpm with about 74% efficiency. I personally have seen 20 psi at that condition. In fact, at 3500 rpm engine speed, it can make 10 psi at about 67% efficiency, or to say it the way you did...33% inefficiency.

One should be careful quoting hearsay as fact.

Don't ask for the map, I don't have permission to share it.

:rolleyes: I think you've got the Ideal turbo then, RJ.

:rolleyes: I think you've got the Ideal turbo then, RJ.
No, I'm telling you that you are spouting numbers that are bogus and you have no clue what you're talking about in that post. I'm telling you that you need to do some research on compressors and that you need to learn how they work because it's clear that you don't know. I don't see why people continue to take your word as truth when you constantly say things that are patently untrue. 30% efficient? Where did you pull that out from?

Then, when I try to correct your errors, you get all offended and act like everyone is picking on you. If you don't want to be corrected when you're wrong, don't be wrong so often. It's that simple.

You make stuff up, spout it as fact and less discerning people think you're "thinking outside of the box." Keep feeding them the swill then, for all I care.

The early '90s PS was mech inj - that wastegate is operated off Boost pressure, and at A/R 60, that turbo is probably less flo than the GM-8.
wow at the quote above, and wow to think that turbo is off of a powerstroke.........in general WOW:shake:

The GM-x is 70% inefficeint above 10 psi or 30% efficeint if your an optimist.
It's valid to the question of intercooling in that how high IAT's climb is a direct result of turbo efficeincy or lack thereof. Intercooling regains some of the efficeincy lost from the compression heat of the turbo. About 30% overall.

That means if you intercool a gm-8 you gain up to 60% efficeincy above 10 psi. With a 60% efficeint turbo you'd gain 90% of your potential efficeincy. This is why grape is matching the perfect turbo (in his estimation) for his truck and IC, just a matter of efficeincy.
I see talk of psi and efficiencies, but no mention of what engine RPM you are feeding or flow rate for that matter...

On edit: I guess RJ asked a lot of the questions that I did.

I'd sure like to see that mysterious IHI rh6f map. I'll admit I extrapolate the known to the unknown but I'd like to be proven wrong, not told I am.

Does any one know if any of the PS, Cummins, or D-Max intercooler inlets and outlets are spaced wide enough to go around our radiator?

powerstroke needs less than 31" tank to tank for a radiator to fit between.

Thanks, grape

Does any one know if any of the PS, Cummins, or D-Max intercooler inlets and outlets are spaced wide enough to go around our radiator?
The duramax IC requires mods to fit, it is about 2" too narrow to get around radiator.

Quite rite, bb - and, as has been mentioned, you've got Kennedy\Spearco, BD\dunnoco, or brew your own, incl Dodge, Ford, or GM.

Problem there is, Cummins and Ford are trying to get 30psi Boost temps down from 300deg, so ~150deg thru the front, between the a\c condensor and the radiator, is very cool, comparatively.

With the 6.5 low Boost, lower output, we'd like to see around 20deg above ambient, for 100deg or so, round trip.

The low mounted c-a coolers are more practical for that useage, as they also do not block the radiator, causing possibly greater heating problems.

If you look at the available real estate between the fan and the grille, you will see the engineering dilemma, with absolute requirement to retain the 20" engine-driven coolant fan.

Yes, The Cummins IC is 46" w x 16" h x 2 1/2" deep and just wide enough to straddle the radiator.

I'd sure like to see that mysterious IHI rh6f map. I'll admit I extrapolate the known to the unknown but I'd like to be proven wrong, not told I am.
You have to have a known first...

I know what heat the turbo produces under different rpm's and boost levels, loaded and unloaded, on my engine. I can subjectively decipher the groaning of the turbo and understand EBP has risen sharply. I know that I have to throttle more than 2200 rpm to make greater than 10 psi boost and I know a bluff when I see one.

Cool. I tried.

I know what heat the turbo produces under different rpm's and boost levels, loaded and unloaded, on my engine. I can subjectively decipher the groaning of the turbo and understand EBP has risen sharply. I know that I have to throttle more than 2200 rpm to make greater than 10 psi boost and I know a bluff when I see one.
My 6.5 would cruise empty at 2000-2200 with 10-12 psi with the OE turbo as best I recall.

Well, I just put in a freash auto tranny. I'll see if the boost builds at a lower RPM. I can see how a slipping tranny might effect that.

Sorry grape - I wasn't intentionally ignoring your hastily-pointed barb...........................

I think the M(T)-25 says it all, don't you?

If not - that 1/4" tubing fitting in the compressor housing pretty much gives it away, at least for any left on this forum that still thinks inside the box, and the envelope hasn't been pushed clean off the table, and is now lying on the floor..............

I mean - izzat a small turbo, er whut? ! ? ! ?

Different 'Strokes fer different folks, dude - word, up!:cool:

bowtie, i got mine off of ebay for about $200:
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=7958274669&category=33742

it is alot larger than it looks in the pictures. it should work well for what i need.

glad to hear you got your goods! let me know if you need anything more.

Sorry guys the question was "What intercooler are you using", not what turbo are you using. I am interested in innercoolers not turbos, my stock turbo is plenty capable, but I have no intercooler. I think the thread will have better responces/information if you stick to the subject.

Thanks,
Yur right boisebiker and this thread has been hijacked with other wishing to throw barbs at each other about whatever is out there to throw them over. I, for one, am sorry that you and other new members have to read this stuff, which has been getting worse in the last few weeks. Please don't let the few spoil your chance to really learn from everyone here , or share what you may know that we don't understand yet. :offtopic:

Sorry guys. I'm looking forward to having some install pictures on my IC's as soon as I can. I'm looking into the plumbing too.

Here's where the thread was hijacked and by whom.

Here's what I'm replacing my GM-4 with. It should push more air with less heat to cool down.
WOW Looks about the size of a small gas engine LOLJudging from your quote above, bowtie, you didn't have a problem with it. Only when rational people step in to correct errors do you have a problem. By the way, I know who your veiled accusations were aimed at.

The truth is a scary thing...to those who are in the dark.

Now, on the subject of intercoolers. You guys have proven my point once again. There are some good kits out there with intercoolers designed for these trucks. One in particular, the Kennedy/Spearco, is probably the best overall system from a value/performance perspective. The hackers here all suggest fabbing a system with some e-bay, who-knows-what core for low bucks. That's fine, but these will not perform as well as a system that has some engineering applied to the design for these trucks. Same guys that complain about no vendor support again steering people away from the few vendors who do support our trucks. Ingenious.

It's funny. Some people have a free pass to spout all kinds of bogus information. Others with informed opinions are viewed as the bad guys. I find that quite amusing.

Here's where the thread was hijacked and by whom.


Judging from your quote above, bowtie, you didn't have a problem with it. Only when rational people step in to correct errors do you have a problem. By the way, I know who your veiled accusations were aimed at.

The truth is a scary thing...to those who are in the dark.

Now, on the subject of intercoolers. You guys have proven my point once again. There are some good kits out there with intercoolers designed for these trucks. One in particular, the Kennedy/Spearco, is probably the best overall system from a value/performance perspective. The hackers here all suggest fabbing a system with some e-bay, who-knows-what core for low bucks. That's fine, but these will not perform as well as a system that has some engineering applied to the design for these trucks. Same guys that complain about no vendor support again steering people away from the few vendors who do support our trucks. Ingenious.

It's funny. Some people have a free pass to spout all kinds of bogus information. Others with informed opinions are viewed as the bad guys. I find that quite amusing.
Well rj I didn't hi-jack and run away with this. I made a short comment on the size of a turbo and I DID IT WITH A LOL, if you noticed. That was an attempt to lauch and move on. I also told those who were hijacked from I was sorry it happen, but I didn't feel I was solely at fault, I am willing to stand up take my shots where I mess up. I have not posted much lately cause that seemed to be a red flag for some of ya to find something wrong. I don't believe I do this to you or others, If Fact I respect enjoy yours and others point of views about everything and only try to get everyone to see that everyone here has a view point and should be treated as we would like ourselves treated. I can tell that there is some real knowledge and experence coming out when ya speak. I guess it's not the message but the "barb" wire fence it's delivered with. If I have broken my rules above lately then I;m sorry it was taken that way. We all have toes and no one likes them smasched and broken when we error, and ALL of us on earth here do make mistakes. Don't know what else to say cause I feel it will only come back to bite me in my end. As I told TD in the PM i sent him right after posting the above reply, Coming here is getting as bad as going to work for, I hate doing it but I find good comes out of it at times. Who says this I DO, but I'm just another nobody here, right.

NO I don't. I think RJ has great intentions in sharing his knowledge and we would be missing something without him and others here.

I also believe Kennedy has some of the best products out there for out trucks.
and I haven't meant to leave any other feelings, and we should be supportive when we can be

Keep it in check guys

Thanks

the intercooler core sold for our trucks was designed and sold for mustang turbo kits by George at turbo technology back in the late 80's:)

This one (http://turbotechnologyinc.com/Chevy_6.5_intercooler.htm), yes.

This one (http://www.kennedydiesel.com/categoryresults2.cfm?Category=2&SubCategory=67), no. This one is specific for our trucks through Turbonetics (they bought Spearco). Both cores are designed and built by Spearco/Turbonetics.

those are both cute.:)

those are both cute.:)
Now, exactly what is that supposed to mean?

It's cool that you guys all want to put intercoolers in front of the radiator with custom fabrication. In most cases, I would agree that's the right place for it...but not with this engine in these trucks. I can't wait to tow between 8,000 and 10,000 lb. across the Mojave Desert on I-15 with you and watch your trucks overheat while mine doesn't. These things have a hard enough time with cooling without adding the burden of charge air cooling in front of the existing radiator (and all the other heat exchangers in the grill). I havn't said anything about this yet (although one other person did) because you all will scream "bias". Well, we'll see.

That desert senerio would be ideal for a few spray nozzles mounted out in front, pump and a 10 gal reservior. The evap on the surface of the cooling fins should help to bring the IC temps down below ambient, or am I just daydreaming?:blahblah:

RJ, do you or anyone else see the benefit of adding a small fan to either design intercooler for added airflow across it? I bought the Turbo Technologies kit years ago, and want to make it as efficient as possible. I feel that the location of either kit and the angle it needs to be mounted is less then ideal do to the low amount of airflow that can pass through the intercooler. I am thinking of adding a small radiator fan from a small car to boost the airflow, or adding some sort of scoop to force more air while driving.

Now, exactly what is that supposed to mean?

It's cool that you guys all want to put intercoolers in front of the radiator with custom fabrication. In most cases, I would agree that's the right place for it...but not with this engine in these trucks. I can't wait to tow between 8,000 and 10,000 lb. across the Mojave Desert on I-15 with you and watch your trucks overheat while mine doesn't. These things have a hard enough time with cooling without adding the burden of charge air cooling in front of the existing radiator (and all the other heat exchangers in the grill). I havn't said anything about this yet (although one other person did) because you all will scream "bias". Well, we'll see.
my truck is a toy, it won't ever tow anything, it's only job is to outrun your truck with no load;)

Well, I just put in a freash auto tranny. I'll see if the boost builds at a lower RPM. I can see how a slipping tranny might effect that.Just did a short drive and 2200 rpm gives me 6 psi and I don't see 10 psi 'till 2350 and 12 psi at 2400, same as it always did during acceleration. I'll post my empty cruise tomorrow.

RJ,

On thread topic question:

If I understand correctly, the first intercooler you link to is the one that you have to run if you buy a kit and have a non-HD truck (I have a 6 lug 2500) unless you are going to be creative and cobble one under your rig like TD did.
http://www.dieselplace.com/forum/images/smilies/joke.gif Sorry Tim I just couldn't help myself. http://www.dieselplace.com/forum/images/smilies/wink.gif

Now if I understand you and Grape correctly, that unit isn't ANY better than an internet special because it wasn't engineered for our trucks????

So the only intercooler that was engineered is the big spearco that you have to make fit on a LD rig?

I know most of the people whose opinion I respect on this and the other forum say an intercooler is a must, and I agree with them. I just want to make sure I am laying out that extremely hard earned cash on the right thing.
I don't tow very often and when I do it will be an Outback by Keystone 23RS (4360LBS dry weight) travel trailer. I DO live in the desert and I DO tow here. Is WMI the way to go in this heat and non-humidity in my case or do I save my pennies and get a big JK kit and a shoehorn?

Thanks for listening everyone and I appreciate any advice at all.

This one (http://turbotechnologyinc.com/Chevy_6.5_intercooler.htm), yes.

This one (http://www.kennedydiesel.com/categoryresults2.cfm?Category=2&SubCategory=67), no. This one is specific for our trucks through Turbonetics (they bought Spearco). Both cores are designed and built by Spearco/Turbonetics.

Now, exactly what is that supposed to mean?

It's cool that you guys all want to put intercoolers in front of the radiator with custom fabrication. In most cases, I would agree that's the right place for it...but not with this engine in these trucks. I can't wait to tow between 8,000 and 10,000 lb. across the Mojave Desert on I-15 with you and watch your trucks overheat while mine doesn't. These things have a hard enough time with cooling without adding the burden of charge air cooling in front of the existing radiator (and all the other heat exchangers in the grill). I havn't said anything about this yet (although one other person did) because you all will scream "bias". Well, we'll see.
Ron, I would bet that the intercooler set up like you have and one mounted in the grill while retaining the factory fan set up would perform very close to each other that the coolant temps would not change. Why do you think otherwise?

Now, exactly what is that supposed to mean?

It's cool that you guys all want to put intercoolers in front of the radiator with custom fabrication. In most cases, I would agree that's the right place for it...but not with this engine in these trucks. I can't wait to tow between 8,000 and 10,000 lb. across the Mojave Desert on I-15 with you and watch your trucks overheat while mine doesn't. These things have a hard enough time with cooling without adding the burden of charge air cooling in front of the existing radiator (and all the other heat exchangers in the grill). I havn't said anything about this yet (although one other person did) because you all will scream "bias". Well, we'll see.
RJ would this still be a problem after installing the upgraded cooling system, and maybe removing the transmission cooling from the radiator, as a few of ya have done,( I don't worry about transmission cooler with mine). I know a bunch of you have run that under bumper mount, but it scares me cause if I want to get somewhere over there, I'm going. That is the only worry about kennedys kit that I have. The kit look well designed and built to me. ):h

my truck is a toy, it won't ever tow anything, it's only job is to outrun your truck with no load;)HEy Grape you only outrun trucks or do you pick on cars too. I got one I can bring out of retirement for you. :joke: :lol:

I also don't tow as heavy as some people here often do. I just looking for something to make power when needed and run all day when needed?

RJ,

On thread topic question:

If I understand correctly, the first intercooler you link to is the one that you have to run if you buy a kit and have a non-HD truck (I have a 6 lug 2500) unless you are going to be creative and cobble one under your rig like TD did.
http://www.dieselplace.com/forum/images/smilies/joke.gif Sorry Tim I just couldn't help myself. http://www.dieselplace.com/forum/images/smilies/wink.gif

Now if I understand you and Grape correctly, that unit isn't ANY better than an internet special because it wasn't engineered for our trucks????

So the only intercooler that was engineered is the big spearco that you have to make fit on a LD rig?

I know most of the people whose opinion I respect on this and the other forum say an intercooler is a must, and I agree with them. I just want to make sure I am laying out that extremely hard earned cash on the right thing.
I don't tow very often and when I do it will be an Outback by Keystone 23RS (4360LBS dry weight) travel trailer. I DO live in the desert and I DO tow here. Is WMI the way to go in this heat and non-humidity in my case or do I save my pennies and get a big JK kit and a shoehorn?

Thanks for listening everyone and I appreciate any advice at all.
No one that I know of has installed an electric fan on one of the low mount intercoolers. That's not to say it isn't a good idea. I've often thought of doing just that, but so far, have had no need to do so. That rubber flap that comes with both is very good at forcing air through the intercooler. It takes much less speed than most people think to get sufficient air flow across one. If you spend a lot of time crawling at less than 10 mph off road, then an electric fan is probably an even better idea.

While the big Spearco is probably the best for the HD trucks, the little one from Turbo Technologies is still pretty good. The Project Truck from the Diesel Page has run one of these for over 160,000 miles and has performed very well towing very heavy trailers. I don't like the fact that one of the tubes gets routed outside the frame rail, but it does work. While it is true that the core was engineered for something else, the tubes were laid out for these trucks and the kit fits nicely with minimal modification required. It is also much less expensive than the bigger kit.

Ron, I would bet that the intercooler set up like you have and one mounted in the grill while retaining the factory fan set up would perform very close to each other that the coolant temps would not change. Why do you think otherwise?
When towing back from the Diesel Page Rendezvous and Pull-Off through Montana and Wyoming last summer, I encountered near 100F ambient temperatures. My coolant temperature ran right on the border line quite a bit of the day. Had an intercooler been mounted in front of the radiator increasing the inlet temperature to the radiator, I probably would have over heated. Likewise, the efficiency of the intercooler would be compromised as well because of the increased resistance to air flow through all of the heat exchangers.

In a system, like on the newer trucks, where all of this has been accounted for in the design of the heat exchangers, everything works like it should. The 6.5, however, is not such a case. The cooling system on the older trucks was insufficient (putting it nicely) and adding any more heat load in series behind the grill is a bad idea. The newer systems with increased capacity water pump and dual thermostats is much better, but is still short on capacity. I did the HO pump and dual t-stats before installing the intercooler and KD fan clutch. Went towing to California in June of 2003. Had multiple overheating events where I had to pull over to get things back under control. The fan clutch and intercooler were the final pieces in the puzzle to allow heavy towing at speeds of 75 mph west of the Mississippi. I also switched to 180 degree stats after the trip last summer.

Your results may vary, but my experience tells me that I don't want an intercooler in front of my radiator on the 6.5.

my truck is a toy, it won't ever tow anything, it's only job is to outrun your truck with no load;)
I'm game any time...

After running no load, lets hitch up a 12,000 lb trailer and do it again.):h

RJ would this still be a problem after installing the upgraded cooling system, and maybe removing the transmission cooling from the radiator, as a few of ya have done,( I don't worry about transmission cooler with mine). I know a bunch of you have run that under bumper mount, but it scares me cause if I want to get somewhere over there, I'm going. That is the only worry about kennedys kit that I have. The kit look well designed and built to me. ):h
See my post above.

Just did and thanks

RJ

The difference in price between the 2 Intercoolers is ~$200.

Bigger here is better.

And, if you have not, check out Turbine Doc's photos, in his sig, for installation details of the large JK\Spearco unit in his K1500.

So in this case size DOES matter after all. LOL

I can't wait to tow between 8,000 and 10,000 lb. across the Mojave Desert on I-15 with you and watch your trucks overheat while mine doesn't. These things have a hard enough time with cooling without adding the burden of charge air cooling in front of the existing radiator
Okay you crazies let me know when this is going to happen so I can hook up my NON-Intercooled truck too my 22 foot camper early in the morning tow it up too our favorite little campsite next to the Blackfoot River here in Montana. While you guys are toasting you engine I'll be wading in the river with a fly rod in my hand and at the end of it all, I drink a ice cold beer.:lol:

Okay you crazies let me know when this is going to happen so I can hook up my NON-Intercooled truck too my 22 foot camper early in the morning tow it up too our favorite little campsite next to the Blackfoot River here in Montana. While you guys are toasting you engine I'll be wading in the river with a fly rod in my hand and at the end of it all, I drink a ice cold beer.:lol:NOW THAT'S WHAT I'M TALKING BOUT, YOU GOT ROOM FOR COMPANY TO WATCH WITH YOU???:exactly:

I hope I have enough radiator for behind my intercooler. Stock vs. my butchered up peice............

NOW THAT'S WHAT I'M TALKING BOUT, YOU GOT ROOM FOR COMPANY TO WATCH WITH YOU???:exactly:
Yes sir always room for good folks to enjoy life in Montana.:cool:

I hope I have enough radiator for behind my intercooler. Stock vs. my butchered up peice............
Grape what are you going to run for a fan??

I like that radiator!

Carey

I think the really BIG question for that BIG radiator is : how are you gonna get only 70mph air to flow thru that 180mph monster, grape?

I think the really BIG question for that BIG radiator is : how are you gonna get only 70mph air to flow thru that 180mph monster, grape?
it cools 700 hp with less than 20 square inches of grill opening at 180, the front of my blazer ought to be open enough for that at under 70 for 300 hp.

I hope I have enough radiator for behind my intercooler. Stock vs. my butchered up peice............

As 'Red 2' said on the approach run to the Death Star, "Look at the size of that thing"...


Holy Crap, batman! How much coolant will that moster hold? Do you have to carry a tanker drivers license? :eek: :ro)

Sweet Piece..

Tim

the radiator alone holds around 3 gallons. Before nascar started the impound thing, we would tape the grill solid and run another 4-5 gallon reservoir tank between the radiator and the lower radiator hose. When that was filled with ice water we could run 2 laps anywhere with no airflow across the radiator, we had almost 60 pounds of water on the nose for qualifying.

NASCAR? Which Team?

Just trying to keep this thread alive because I still have'nt got the information I was originally looking for.

Who has an innercooler? Where did you get it? How much was it?

I know a few of you have them, tell us about it. Did you install it? How do you like the results?

Good Question, I believe GMCTD, Ronniejoe are amoung the inter:cool2: ed bunch here

I have the Spearco intercooler its smaller than some and I bought it from DSG here in Canada. Installed it my self, biggest problem was getting the hoses to NOT blow off, had to buy better clamps. It made a huge difference pulling my fifth wheel, we were to the point of looking to buy a dmax because my truck was having a hell of a time pulling the trailer without sending pryometer through the roof. Put on intercooler it was like a completely different truck, pulled through the mountains going to BC without a problem. Truck always had lots off power to pull just couldn't keep exhaust temp below 1200 even on flat ground, and now on flat ground I can set cruise on and not worry.

Yes - if JK lived in the south of france, he'd be selling Chausson, rather than Spearco.

Mine's an '80s style truck, so I'll leave the details to those with the '88-up series.

If you tow, you need a charge-air cooler - recovers lost power, even in a stock truck.

Got it?

Get it.

Go to the weblink in my sig, for the how, the where was Kennedy check his site for current price, depending on your needs WMI costs less from Bill Heath, but for "set & forget" simplicity always working IC is way to go IMO.

Just trying to keep this thread alive because I still have'nt got the information I was originally looking for.


Who has an innercooler? Where did you get it? How much was it?

I know a few of you have them, tell us about it. Did you install it? How do you like the results?

Here's 15 min of disassembly. I'm about to move the radiator and condensor toward the fan and each other, then get the sawzall and make some room.

Just a side note:

Installing a good sized intercooler will also lower the engine coolant temperatures, in addition to IATs, so you don't need that big of a radiator any more.
That's why I got the 31x19 aluminum rad from UniversalParts to fit inside the PowerStroke unit.
Two 14'' electrical fans will do it as far as blowing thru it IMHO.
No more factory 20'' power hog.

You need to check the flow rating on those electric fans. They're probably about half what that 20" power hog will pull.

Since I had it off, I installed the (saub 900) IC and made a cold air intake. I only had to move the condensor 1" and trim a little metal and plastic. Now, I just have to plumb it as you can see in the last two pictures there's plenty of room, but I might flip the upper plenum for the return off the IC to come around to the other side. Time to testdrive and check out the coldair intake.

Here is my intercooler in front of the grill.

Far away:
http://img.photobucket.com/albums/v622/dieseldummy/intercooler3.jpg

Close:

http://img.photobucket.com/albums/v622/dieseldummy/intercooler1.jpg

Under Hood:

http://img.photobucket.com/albums/v622/dieseldummy/intercooler2.jpg

I have been running this setup for 1.5 yrs. now and have had only good things happen as a result. It helps keep IAT temps in check, it is built with a intercooler from a tractor with an M11 cummins that I trimmed down a little bit and a bit of exhaust tubing and ruber hose. At this time I only have the HO water pump, duramax fan, and modified '97 fan clutch as cooling mods and the coolant temps stay below 220. This is running a -4911 IP maxed out and a Holset turbo pumping out 20+ lbs of boost. I'll try and get some better pics later.

As a side note, before anyone rips me for not supporting a vendor such as John Kennedy, Bill Heath, or whom ever let it be know that I am a general tight ass, but when I need something that I can only get from a vendor I support those who support the various web sites I think are valuable such as this one. Example: I just finished scrounging the last bits of my step by step cooling mods together and was in need of some thermostats, I desired the Robertshaw stats so I ordered some from JK...

I like it. I'm going to insulate the outlet off the turbo back to the intake but that's what I was thinking it would look like


I noticed the upper plenum has the '94-'95 look.

Here is my intercooler in front of the grill.

Far away:
http://img.photobucket.com/albums/v622/dieseldummy/intercooler3.jpg

Close:

http://img.photobucket.com/albums/v622/dieseldummy/intercooler1.jpg

Under Hood:

http://img.photobucket.com/albums/v622/dieseldummy/intercooler2.jpg

I have been running this setup for 1.5 yrs. now and have had only good things happen as a result. It helps keep IAT temps in check, it is built with a intercooler from a tractor with an M11 cummins that I trimmed down a little bit and a bit of exhaust tubing and ruber hose. At this time I only have the HO water pump, duramax fan, and modified '97 fan clutch as cooling mods and the coolant temps stay below 220. This is running a -4911 IP maxed out and a Holset turbo pumping out 20+ lbs of boost. I'll try and get some better pics later.

As a side note, before anyone rips me for not supporting a vendor such as John Kennedy, Bill Heath, or whom ever let it be know that I am a general tight ass, but when I need something that I can only get from a vendor I support those who support the various web sites I think are valuable such as this one. Example: I just finished scrounging the last bits of my step by step cooling mods together and was in need of some thermostats, I desired the Robertshaw stats so I ordered some from JK...
dieseldummy,

Can you get to your factory fuel filter or did you move it?

I like your IC install!!

What brand grill guard is that?

Carey

Carey,
I have to take off upper plenum to change fuel filter, always keep a 10mm wrench and a 5/16's nut driver handy in the tool box... Been meaning to relocate it with a better lift pump to the frame rail. I think the grill gaurd is a Luverne(?spelling). Thanks for the kind words as well, I usually get made fun of for hacking up my grill.

Sweet, i posted that upper plenim configuration a couple of weeks ago, now i get to see it before i do it! Thanks for the pics.

I lightend the image and I can see what you mean.

Can I ask what kind of milage you get with this setup?

QM, Thanks for touching up the image, I'm not real good with pics. Currently been getting 15-17 mpg around town depending on conditions, been as low as 9 mpg towing way to much weight at to high of a speed...

would that be the Sabb IC i seen on ebay for sale? looks like it fit better than i thought it would.

I had to do more sheetmetal trimming on the air intake than the IC.

This is great stuff, just what I was looking for. Will give me a lot to think about before installing my own setup.
Keep up the great flow if information, I am sure this is helping a lot of guys. And the pics say a thousand words.

QM, you got an intercooler from Audi 5000 turbo (pictured).
It is not the SAAB one.

You're right.

You are bidding on a used but in good condition AUDI 5000s trubo FMIC/intercooler has hardplastic end tanks pretty big intercooler and great custom turbo application it measures 7" high 19" wide and inlet/outlet is 2 1/4" diameter.

The other two I have are a supra, and rx7. no more saab stories :bawl:

Just glue all three of them together and you got a nicely sized unit, a la powerstroke. :)
Actually Audi's unit is pretty rare, and popular in DIY world, since it's got 90 degree outlets - easy to adapt, I was thinking about putting it inline between the turbo and the intake - Subaru style, at one point.

I started to passionately hate factory's upper intake snorkle.
Its ugly, its non fixable (impossible to cut and reweld) and it faces the wrong direction.
Was pondering of using the N/A lower intake (round base) and weld a flipped aluminum bowl with a piece of 3'' tube onto it, anybody sees any problems with that (making an intake a single piece unit)?

Shakmobil,

How about a piece of 5/8 or 3/4 steel plate drilled to fit the existing bolts, then cut round hole just the right size (looks like about 3") to match one of those cast elbows off of a mid-90's cummins. I see those elbows for sale regularly on ebay for a few bucks. You could then drill & tap the 4 boltholes to aim the elbow the right direction. Then you just cut two matching gaskets and bolt the whole thing on top of your 6.5 TD. You might have to drill/tap one more hole for your boost gage!

Cool idea, thanks.
I just don't like marrying aluminum and steel together on top of a very hot engine. Could be an aluminum plate (1'') though.

i have a freind that has a water jet machine, it comes in handy;)

I can hardly wait until you get to give us some numbers on that thing!

(and let us know how far it rolled after the bottom end fell out) Just kidding!

I can hardly wait until you get to give us some numbers on that thing!

(and let us know how far it rolled after the bottom end fell out) Just kidding!I'm going to be upset if it runs just long enough to get the oil dirty before it sprays it all over my truck. I'm having some main caps built right now, the crankshaft that i have is new in the box, yet that thing is scary looking in some places. If i get more serious I'll get crower or cola to cut me a crank out of billet......like the camshafts i had built.:o:

what are you doing to the main caps? Is the new crank you have there a stock crank?

Grape,
Those are great pics - I assume they are of your truck. A few questions:
1. What year truck is it ?
2. That looks like a PowerStroke IC - right ? What radiator do you plan to put behind it, and what is its width - out-to-out ?
3. Since my radiator ('95 6.5TD) is 41" out-to-out, I have been dreaming of putting a mid-'90's Cummins IC in front of it - BIG problem is that the 3.5" nozzles aren't quite wide enough ( 38" in-to-in). Since I haven't puzzled an answer yet, I am wondering if another radiator(from another year GM or perhaps from a Dodge) might be sandwiched in there. Do you have any sugestions to solve this dilema AND still be able to use the AC condenser, oil coolers, etc. ?

Can you tell us any more about the pics?

Grape,
Those are great pics - I assume they are of your truck. A few questions:
1. What year truck is it ?
2. That looks like a PowerStroke IC - right ? What radiator do you plan to put behind it, and what is its width - out-to-out ?
3. Since my radiator ('95 6.5TD) is 41" out-to-out, I have been dreaming of putting a mid-'90's Cummins IC in front of it - BIG problem is that the 3.5" nozzles aren't quite wide enough ( 38" in-to-in). Since I haven't puzzled an answer yet, I am wondering if another radiator(from another year GM or perhaps from a Dodge) might be sandwiched in there. Do you have any sugestions to solve this dilema AND still be able to use the AC condenser, oil coolers, etc. ?

Can you tell us any more about the pics?


my truck is an '82 k5 blazer, so it's the old bodystyle. I have pictures of my radiator back on page 7 i think, it was miled out of one of our race trucks. I don't see any way to do it without changing radiators to fit the particular intercooler you choose.

What is the optimal piping size? Do you want to go with 3" to get better flow characteristics? Or do you want to go with the turbo discharge flange size for less turbo lag? What is the turbo discharge size anyway? Same question on the intercooler, is bigger better on the inlet and outlet?

my inlet side outlet is 2.5", it transitions up to 3" because the powerstroke intercooler is a weird 3.25" od. After it gets out of the intercooler it runs 3" back into the engine. Not sure what it needs, everybody seems to be able to make 300 hp with 2.5" inlet tubing so I'm not sure if we'll have any lag issues or not. It would also be hard to compare to anyone else because of the inlet wheel I'm using, along with the size of the exhaust wheel, both sides on my turbo are larger than what people are making 300 hp with.

I keep it 2 1/4" t match the IC I put in but I got this pipe bentout for $30.

I keep it 2 1/4" t match the IC I put in but I got this pipe bentout for $30.
QM,

Where did you get that bent at???

Carey

The local mayco franchise. The guy running it is cooler than s**t.

Been doing more research on intercoolers. Man is this going to be a tough one. No place to put a decent sized cooler. Can't go infront without cutting grille and moving exsisting coolers forward. Right now I am considering under the front, but there are not any stock intercoolers that will fit that location. It is the inlet and outlet location that are killing me. If I spent $400+ I can get what I want and I think it will be large enough to do the job with authority. But I was trying to go the $100 rought. The question I have is, what is the core size every one is using and do you think it is enough?

one thought on the intercooler in front of the rad position. No question the intercooler would restrict air to the rad in some way. But, the rad would also be dealing with less heat, since the IC had reduced the coolant temps. It seems to me there would be a combo effect: either the rad deals with all the heat, or the load is shared by the rad and IC.

ROGER THAT!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

my truck is a toy, it won't ever tow anything, it's only job is to outrun your truck with no load;)

Here is another question, how much air does this beast take(CFM)? I read somewhere that a slightly midified 6.5 uses 840 cfm, that is with an exhaust and intake mod. What does everyone else think? I am trying to size my intercooler.

The bigger, the better. Period.
I'm going the first gen powerstroke unit (19x34x3 core). Biggest one I've seen so far. Otherwise it is just not worth it, since you'll see 1.5-2 psi drop in boost anyways.

Hey Shak, Noticed in your sig "Got 70 SS?" Just wondering what you got? And yes as a matter of fact I do! :ro) Got pics?

Hey Shak, Noticed in your sig "Got 70 SS?" Just wondering what you got? And yes as a matter of fact I do! :ro) Got pics?
You are a lucky dude. I had beautiful 70 SS 396 in high school and kick myself daily for selling it. I hope to someday get another one.

Yeah, I know.....real lucky. One of my Dad's best friends had it sitting is his barn for years and one day mentioned he was thinking of selling it. Don't think the phone had hit the receiver before we were on our way to go get it. The only problem is now, I am scared to drive it most of the time. Most people just don't understand what a muscle car is to the enthusiasts and owners.

Is it an LS5 or LS6?

I have a 1970 Camaro SS, not a big block - 350 LT1, still plenty ;). Have some pics, it is still a work in progress. The mechanicals take priority over body work/paint.
And yes, I know what you mean when you say "I'm scared to drive it...".

Is it an LS5 or LS6?
How does LT1 rate in your book? lol

The LT1 is a stout motor. Ours is home to an LS-7. As to how it got there, is a mystery. We have had GM restorations involved and traced it back through all previous owners. GM has verified it as a true SS car and as a real experimental LS-7. They haven't come up with any documentation to put the 2 together yet though. To be honest, I don't really care. I won't sell it anyway.;)

The LS7 was rumored to have been put into 7 cars by General Motors.

The 1970 Chevelle was not one of them.

They were all 1970 Corvettes.

Nickey and Baldwin Motion set up Camaro SS and Chevelle SS, even a few El Camino SS, with that big rat............

I think Joel was a fan of the 427...

QM do you have any numbers on your truck with the inter cooler yet?
Do you find it runs better now?
Give us some details
Thanks

Milage is better if I can drive slowly but when I get my foot into it, it's all relative. IAT's dropped 150*F at WOT from ~300*F to 150*F, that's a cut in half. The turbine whistle is the same but the 10+ psi air noise from the turbo has deminished. I like it and am glad it's inplace. The IC on the '96 is ready for testing too, but I don't have a OBDII scantool right now.

Rite on , that set up could be all i need aswell .
Would it improve the egts of pulling a 5000lbs trailer, because i am scared of it over heating
THANKS

So far this year my egt's haven't moved more than 10*F during the most intense of WOT's. :P

Rite on , that set up could be all i need aswell .
Would it improve the egts of pulling a 5000lbs trailer, because i am scared of it over heating
THANKS
Flan until you start modding your truck you should be okay, if bucks are a problem do a little as you can afford it; keep less than 10 psi boost and open exhaust & gages; only towing 5K while driving by EGT you will also be okay for mostly flat towing.

Add some hills on a hot day, retuned fan clutch, deep trans pan or aux trans cooler & a little boost fooling you should not need an IC, high boost and higher loads you will need to do some more mods or be content to back off when temps climb

flanman, i just got done towing a gooseneck with two gravity wagons on it for about 160 miles. trailer weighs 6400 pounds and the wagons weight about 2000 a piece. goin 57 mph in 3rd w/torque converter locked up @ 2300 rpms my post pyro temps were only at 6 or 700. i had the turbomaster cranked at 2" untill i set a code then i backed it off to about an inch and a half. i wouldnt worry too much about overheatin with 5000 pounds. these wagons were 13 foot in the air. lot of wind resistance. my coolant temp never got to 210 F.