What is the best size for the intercooler on a turboed 6.2 or 6.5? I have access to some for a road tractor type truck. Is it possible to cut one down? I have access to a unit to weld the alum back up. How about the pipe layout on the intercooler does it matter on the in and out?

Well, the bigger you can fit in there the better, but that has always been the problem with a 6.5, there isn't much room unless you want to get creative and do a little fabrication. I like what a few others have done on here by taking off the factory fan assy and replacing it with a good electric set up, moving the rad back as far as they can and then mounting thier custom IC in front of the rad behind the grill. It would seem to me that this is going to be the most easily efficient set up. I think if I had to do it all over that is what I would do if nothing else just because you can get a bit bigger IC in there instead of where mine is at the bottom front where the skid plate used to be.

Here's a '94 k2500 F engine 6.5L I'm helping to transform from the truck everybodies honking at as they pass to the one that's doing the passing. The owner made his bumper for a winch but there's enough room for both the winch and an hudge IC core.

Are those nipples below the nostrils, must have been cold the day the pic was shot the way they are sticking out ):h "Check it out-that truck has a set of cones"

Check the web link in my sig dimensions of the IC are there, the Spearco kit I installed is about the largest IC that will fit with any ease in the under bumper location.

Kit can be bought from Kennedy, here is the kit description from Turbonetics web site
http://www.turboneticsinc.com/kits.html

6.5 Chevrolet/GMC Turbo Diesel Pick-Up/Suburban/Blazer Intercooler System
NOW... the 6.5 turbo diesel can have the same power enhancing intercooler technology used by nearly all of the big, long haul, Class 8, 18 wheelers. Intercooling increases power and torque with absolutely no negative impact on engine durability. Once the initial investment is made, the result is a lifetime of free power and improved fuel economy.

This intercooler system reduces charge air temperature entering the engine, increasing the air density for increased power and torque, while reducing the overall thermal load on the engine and cooling system as exhaust temperature is reduced as much as 150ûF. This results in less transfer of heat to the cooling system and assists in maintaining normal coolant temperature on long hard pulls towing high gross weight vehicles. Since the intercooler is mounted between the "frame rail" below and behind the bumper there is no impact on the engine cooling system. Air traveling beneath the vehicle is trapped between the road and the bottom of the intercooler, which gives the intercooler excellent performance even at low vehicle speed.

In addition to power and performance, you can anticipate an increase in fuel economy as the cooler, denser air creates a lean air/fuel ratio and in conjuction with less heat loss to the cooling system, fuel mileage can increase from 4% to 7% depending on driving conditions, weight towed, etc. Approximate installation time is 5 to 7 hours.
Part 2-435 Series 2500, 3500 2-wheel drive pickup/Suburban 1993-94
Part 2-436 4-wheel drive pickup/Suburban/Blazer 1993-1997
CARB EO# D-140-29
Back To Top

This link takes you to size & flow charts of various Spearco IC cores http://www.turboneticsinc.com/air.html

I was going to suggest the guy with the bumber get a better deal on his IC than the kits 'cause he's a disabled vet and lives on disability. His bumper could easily fit anything that will fit between the frame members ~32" width.

Check the web link in my sig dimensions of the IC are there, the Spearco kit I installed is about the largest IC that will fit with any ease in the under bumper location.
Don't stumble crossing the street when this bad boy rolls by, those are shapened spikes. This bumper gives new dimension to what will fit or not, it's at least three times bigger and comes out 12". You can easily stand on it to do your maintainence.

Don't stumble crossing the street when this bad boy rolls by, those are shapened spikes. This bumper gives new dimension to what will fit or not, it's at least three times bigger and comes out 12". You can easily stand on it to do your maintainence.
That bumper looks real close to the ones we built in Alaska back in 1991 or so. cept where those spikes are we put two 2" recievers which opens alot possiblies as too what could be installed in them, from seats to steps. I used mine alot to pull other out of bad places the got stuck in.