Shawn MacAnanny
Full Access Member
All i have left is some wiring, i'm waiting on some fuses to finish up. I have 3 temperature probes that ill just be taping with foil tape to Inlet of Turbo, Inlet of IC, and outlet of IC to monitor efficiency. They each have an LCD display in the cab. The intercooler is rated for 700CFM, i have a Johnson pump thats rated at 6.9gpm though they do make a 22gpm i may upgrade do it i dont get the heat transfer i want. The kit shipped with a single 10" fan, i installed 2. I have a thermal switch that will activate the 2 IC radiator fans when truck coolant gets to 80F. This will help with cold starts. I have the coolant pump running all the time from fuel pump relay. The IC fans, and radiator fans are on a delay timer, they have power to their circuit 60 seconds after the truck has been started, i did this to prevent them from coming on when glow plugs are on and come putting a strain on the alternator at idle.
I know the CAI is very home made, it's just galvanize heating/air piping. Its a 6" to 8" reducer that the K&N filter fits in perfectly and seals air tight around the fitting so it must pull from the bottom. I just foil tape them together rather than bolting/riviting so i can take it apart easier to inspect and clean filter. The bottom is an adjustable 8" elbow from lowes too. Both parts were around $20 together or so. I didnt want the filter open down there catching water directly that would be spraying from the tires or off of the radiator core. This will also direct it to pull air from below the radiator which should in theory be colder than whats inside. Upsizing to 8" should be big enough that it wont lift rain verticle into the fitler housing, 700cfm in 8" pipe should only be like 22mph and thats not enough to lift water.
All the clamps and silicone fittings i got in an ebay kit for $99 with the exception of the reducer fittings for the intake hat and turbo. The air intake for the turbo is also resting on 2 injector lines, just barely. The silocone couplers are there just to prevent rubbing. If i took them off the intake actually isnt touching them, but i wanted the added peace of mind that it wasnt going to rub my injector lines.
I added a 1 gallon reservoir that i drilled and tapped to be a flow through reservoir to ensure the pump stays charged and all air bleeds out. Coolant is pump in from the bottom of the IC and out the top (since heat rises), goes to the reservoir, it's then returned to the top of the IC radiator and drawn from the bottom of the IC radiator with the coolant pump.
I mounted the IC using two of the AC fan bolts with two 6" angle brackets i got from lowes that i bent and welded together
I know the CAI is very home made, it's just galvanize heating/air piping. Its a 6" to 8" reducer that the K&N filter fits in perfectly and seals air tight around the fitting so it must pull from the bottom. I just foil tape them together rather than bolting/riviting so i can take it apart easier to inspect and clean filter. The bottom is an adjustable 8" elbow from lowes too. Both parts were around $20 together or so. I didnt want the filter open down there catching water directly that would be spraying from the tires or off of the radiator core. This will also direct it to pull air from below the radiator which should in theory be colder than whats inside. Upsizing to 8" should be big enough that it wont lift rain verticle into the fitler housing, 700cfm in 8" pipe should only be like 22mph and thats not enough to lift water.
All the clamps and silicone fittings i got in an ebay kit for $99 with the exception of the reducer fittings for the intake hat and turbo. The air intake for the turbo is also resting on 2 injector lines, just barely. The silocone couplers are there just to prevent rubbing. If i took them off the intake actually isnt touching them, but i wanted the added peace of mind that it wasnt going to rub my injector lines.
I added a 1 gallon reservoir that i drilled and tapped to be a flow through reservoir to ensure the pump stays charged and all air bleeds out. Coolant is pump in from the bottom of the IC and out the top (since heat rises), goes to the reservoir, it's then returned to the top of the IC radiator and drawn from the bottom of the IC radiator with the coolant pump.
I mounted the IC using two of the AC fan bolts with two 6" angle brackets i got from lowes that i bent and welded together
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