Diesel Place banner

1 - 20 of 71 Posts

·
Registered
Joined
·
627 Posts
Discussion Starter #1 (Edited)
After installing the HX40WII on my truck, I can easily hit 20+ psi of boost if the boost controller is set there. That got me to thinking about installing an CAC, but all the available kits cost over $900 after shipping! :eek: There is now way I could afford to go that route, but after checking prices I realized it could be done for about $300. I read a thread done by sctrailrider on his CAC install, and mine will be similar.
I decided to go with the bar & plate type CAC over the tube & fin design. Both designs have their pros, and cons, but the deciding factor for me was bar and plate design is more resistant to damage from rocks, debris, etc.. The CAC size is 31x12x3.25. I will take lots of pics, and try to show everything that it takes to get it installed in my 93 K2500. This is my first time installing a CAC, but it looks like it should be a pretty straight forward job. Hopefully. :think:

Here are the prices, and links to the parts being used.

$60 Peninsular upper intake. I got mine from a fellow member, but here is the factory link, and we'll use their price for the sake of trying to make the price repeatable for anyone wanting to do this.
2335520 Air Intake Adaptor | Peninsular Engines
$98 Intercooler. 31x12x3.25 Bar $ Plate
Bar Plate Lightweight Aluminum Turbo 31"x12"x3 25" Fmic Front Mount Intercooler | eBay
$93 Installation kit. Should have all necessary bends needed.
DIY Custom 8 Piece Silver Pipe Intercooler 3" Piping Kit w Blue Coupler VW Euro | eBay
$15 45* silicone 2.5" to 3" silicone elbow. For coming off the turbo, and this is the only one that I believe I will need seperate of what comes in the install kit.
Silicone 45 Degree Elbow Reducer 3" to 2 5" 76mm to 64mm Turbo Silicon Blue | eBay

This brings us to $266 currently. I've already ordered the CAC, and 45* elbow, as well as the Peninsular upper. I will order the install kit in the next day or two. :thumb:
I'll be working on a cold air kit as well, as it seems counterproductive to install an intercooler while sucking hot air from under the hood.:Insane:
Here is a pic of the trucks current setup. ( site won't let me upload my pics as they were already used in another thread) I'll take some new pics tomorrow.

Matt
 

·
Registered
Joined
·
729 Posts
Cool.
 
  • Like
Reactions: bowtiebutler956

·
Registered
Joined
·
627 Posts
Discussion Starter #3
The first piece of the puzzle arrived today from a fellow member (Thanks Paul). The Peninsular upper. Here are a couple pics of it, as well as the current setup.

Matt
 

Attachments

  • Like
Reactions: no50svo

·
Registered
Joined
·
846 Posts
Man your engine is insanely nice!! That intake makes everything super easy.
 
  • Like
Reactions: 90dieselk1500

·
Registered
Joined
·
257 Posts
I am aware some are fussier than others, and i am anal about my truck too, but reality is, i live on a gravel road & put on about 25,000 miles a year in michigan climate. With that said, I used 2.5 inch aluminized exhaust tubing when I installed my cac 8 years ago. Still not a spec of rust on any of it. Not sure if there is a big price difference between the kits & exhaust pipe, just a heads up for those that may be curious.
 

·
Registered
Joined
·
3,634 Posts
Something I've thought about with this is putting a drain bolt in the bottom of the intercooler because the CDR puts oil into the air stream then that oil condenses and sits in the lowest part of the system. Might just be me over thinking, but worth a thought....
 

·
Registered
Joined
·
5,861 Posts
Something I've thought about with this is putting a drain bolt in the bottom of the intercooler because the CDR puts oil into the air stream then that oil condenses and sits in the lowest part of the system. Might just be me over thinking, but worth a thought....
No, I agree. I have heard this from a lot of guys with intercoolers. Not a bad idea at all:thumb:
 
  • Like
Reactions: roadhog0

·
Registered
Joined
·
257 Posts
I had the tubes off mine a couple weeks ago doing a pitman arm. No accumulation of oil. There's a highway on ramp in town here that pretty much requires full throttle. On the occasions I use it, I'll usually see a big puff of blue smoke about 3/4 down it. Pretty sure that's the accumulation leaving the intercooler.
 

·
Registered
Joined
·
627 Posts
Discussion Starter #9
Something I've thought about with this is putting a drain bolt in the bottom of the intercooler because the CDR puts oil into the air stream then that oil condenses and sits in the lowest part of the system. Might just be me over thinking, but worth a thought....
Actually, I think thats a fantastic idea, and one I will probably implement. Thanks for the idea. :thumb:

Matt
 
  • Like
Reactions: roadhog0

·
Registered
Joined
·
627 Posts
Discussion Starter #10
Man your engine is insanely nice!! That intake makes everything super easy.
Thanks, and it will be nice to have easier access to intake, and ip.

I am aware some are fussier than others, and i am anal about my truck too, but reality is, i live on a gravel road & put on about 25,000 miles a year in michigan climate. With that said, I used 2.5 inch aluminized exhaust tubing when I installed my cac 8 years ago. Still not a spec of rust on any of it. Not sure if there is a big price difference between the kits & exhaust pipe, just a heads up for those that may be curious.
That sounds like a great idea. Living way down here in deep South Texas, I don't have to deal with much rust, and corrosion, so I think the kit that I posted a link too, will work well for me. Thanks

Matt
 

·
Registered
Joined
·
627 Posts
Discussion Starter #11
Next piece of the puzzle showed up today! :clap: I will say this CAC weighs more than I expected it to, and I can see I'll need to build some sturdy brackets for it. As usual with these china performance parts stores on ebay, their advertised measurements are a little off. The true core dimensions are 23.5x11.5x3. The overall length is 30.75". Its overall quality seems good, and I held it up under the truck, and can see it will fit very nicely.:thumb:

Matt
 

Attachments

·
Registered
Joined
·
846 Posts
Looks good! I agree heavier than expected!! I had to do some fin straightening when I was fitting it under the truck by myself. Had a few choice words after that.
 
  • Like
Reactions: bowtiebutler956

·
Registered
Joined
·
3,634 Posts
Looks a lot like the intercooler I have on the shelf for my truck!
 
  • Like
Reactions: bowtiebutler956

·
Registered
Joined
·
627 Posts
Discussion Starter #14
The piping kit arrived for the intercooler install. :clap: The 2.25" to 3" 45* elbow came in as well. I'm going to be very busy with work this week, but I'll get to the install ASAP! :thumb:

Matt
 

Attachments

  • Like
Reactions: dieselolds

·
Registered
Joined
·
110 Posts
That's WAAAAAY cool! I'm really jealous!

So...where are you going to mount it? Just below the bumper?

I'm excited to see how it all goes! :popcorn:
 
  • Like
Reactions: bowtiebutler956

·
Registered
Joined
·
5,861 Posts
Nice, REAL nice
 
  • Like
Reactions: bowtiebutler956

·
Registered
Joined
·
110 Posts
Not to be a bother, but... :whistle: ......have you gotten any further?
 

·
Registered
Joined
·
627 Posts
Discussion Starter #18
Not to be a bother, but... :whistle: ......have you gotten any further?
No bother at all. I've been crazy busy this week, with my days starting at 6am, and not ending till 7pm. I pulled well over 20 10,000 lb trailer loads loads 30 miles one way with my truck. Truck did amazing. I'm hoping to get started on the CAC install very soon. :thumb:

Matt
 
  • Like
Reactions: MackManiac

·
Registered
Joined
·
9,976 Posts
Can't wait to see the difference. :thumb:

My only 2 cents is those couplers are cheap, and over time, oil can soak thru them and they'll slip off. That happened to me until I upgraded to better units and no more issues.
 
  • Like
Reactions: bowtiebutler956

·
Registered
Joined
·
627 Posts
Discussion Starter #20
Can't wait to see the difference. :thumb:

My only 2 cents is those couplers are cheap, and over time, oil can soak thru them and they'll slip off. That happened to me until I upgraded to better units and no more issues.
Thanks for the heads up TVM, I'll keep an eye on them. :thumb:

Matt
 
1 - 20 of 71 Posts
Top