intercooler setup/fabrication

War Wagon · Feb 16, 2011

Brand new to oil burners. Purchased a '94 F350 7.3 w/factory turbo about a year ago and have some plans and parts for upgrades, but now to my question.

I have the ATS cast aluminum intake piece for an intercooler, but not the rest of the kit. I need to either buy the other pieces or fabricate my own. The only places that make these setups that I know of are ATS, Banks, and Hypermax. Someone must have been here and done this before. What sort of intercooler systems do you guys have on your pickups? I'm looking for some good advise on how to do this on a buget but good reliable quality.
Also Diesel Performance Specialists makes 20 hp stage 1 injectors for the idi 7.3L. Anyone ever try them?

towcat · Feb 16, 2011

you have the piece that's no longer being made by ATS.
if you can handle the cost of $1300, call ATS and they will sell you the rest of the kit that will bolt right in.

Black dawg · Feb 16, 2011

I have an intercooler from a 6.0 in mine, it added a good amount of power. The dps injectors that I tried were poor quality

War Wagon · Feb 16, 2011

To be clear, the ATS piece that I have is the big tall ugly piece with the bolt running through the middle of it that bolts right on top of the intake manifold.

War Wagon · Feb 16, 2011

6.0L intercooler is not too big too much volume for an IDI?

Black dawg · Feb 16, 2011

War Wagon said:
6.0L intercooler is not too big too much volume for an IDI?

I was told it was too big, but man did it make a difference.

towcat · Feb 16, 2011

War Wagon said:
To be clear, the ATS piece that I have is the big tall ugly piece with the bolt running through the middle of it that bolts right on top of the intake manifold.

this piece right?

icanfixall · Feb 16, 2011

Welcome to the forum. Many members have made intercoolers from other trucks fit ours. some have even bought generaic units off ebay and made them work fine. I don't think Banks makes a setup for our engines.... Just make sure your fan clutch is working properly because your pulling air thru a much wider obstruction now...

typ4 · Feb 16, 2011

The only performance injectors that really deliver for our old trucks are Mels Moose Misters. There aren't any "stage 1" anything for theseIDI engines.

Oh and the bigger intercoolers dont hurt anything as far as capacity, moving air is moving air.

Agnem · Feb 17, 2011

Do a search for homemade intercoolers. We a few threads around with lots of pics in them to help you fab up your own.

Dieselcrawler · Feb 17, 2011

soo... 2500 for the burban with no axles. do the boxes come with it?

towcat · Feb 17, 2011

Dieselcrawler said:
soo... 2500 for the burban with no axles. do the boxes come with it?

$2500 was before they guy took on a 3axle heavy towtruck.

If you think I'm cannibalistic on fords, you should see what my family does to 'burbs. individually, my family isn't very big, but I have a shitload of first and second cousins. family gtg's become a logistical challenge on transportation without the 'burbs.

Brad S. · Feb 17, 2011

What would the difference be from a intercooler and a cool air being scooped up from infront of the pickup??

War Wagon · Feb 17, 2011

towcat said:
this piece right?

That is the piece.

Banks makes a cooler for the 94-97 powerstrokes. I was thinking about retrofiting it to my IDI since they are the same body style and building my own plumbing.

towcat · Feb 17, 2011

Brad S. said:
What would the difference be from a intercooler and a cool air being scooped up from infront of the pickup??

cool air coming in is a good thing, but irregardless how cool the air is, getting compressed by the turbo will heat up the air. the intercooler takes care of that problem. generally a IC will take 2-300deg of heat out of the compressed air. lower air temp= denser air=more power and lower egt's. best thing it's a passive power adder and requires almost no maintenance.

intercooler setup/fabrication

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