I have gotten a dodge intercooler for the 6.5 swap into my 80 model chevy dually. I have the 91 style four headlight system on this truck. The inlet and outlet are going to hit my inside headlight on each side. Has anyone here cut around on the intercooler and moved the tubes around? I was thinking about cutting the outlet and moving it down to the center of the core to fit between the headlight and turn signal housing. Can you go to big on the intercooler?

I don't think that you can go too big, as far as cooling goes.

But I'm not sure here, but if you have a long way for the air to go between the turbo and the intake, there will be a lag time in building boost pressure.

Am I right or wrong on this assumption?

I just started to put my intercooler today since I have a few hours to kill and the truck is down due to I cannot afford to drive it with the diesel as high as it is, I spend about 100 a week on that for fuel and my VW rabbit uses about 30 bucks a week, max, at like 500-600 miles of driving. But, on my '98, I have notched the frame horns, trimed the fender wells, about 6 hours of fab and I am sure 10 hours to go after I make brackets and cut the pipe.

Pics very soon.

Oh yea, the bigger the intercooler, the better. You see more pressure loss as you go big, but only like 1/2 to 1 PSI. I have a 24X12X4" intercooler, the area of the cooling surface. The outer dimensions as more like 30X12X4.

i dont see a problem moving the inlet and outlet on the IC, but i would only take that move if i had NO other choice.

have you concidered installing it under your core support between the frame rails?

take a look at this link:
http://dieselplace.com/forum/showthread.php?t=39502

this is just another possible solution.

$100/week for fuel, your doing good. I'm spending about $150 every 3 days!