Intercooler system costs?

saburai · Oct 19, 2017

Hi Gang!
I'd like to install a intercooler on the old mule now that he's turbo'd, can you say mission creep

? I know you can...
Anyways, I'd like to keep the stock airbox and I was looking at the Hypermax intercooler kit at $1500 it's a complete bolt on other than cutting the holes for the pipe.
If I were to piece together my own system, how much do you all think that I'd spend on something comparable? Please keep in mind that I don't weld and if there were welding involved, I've got a few connections, but it'd still in cost me. What if I were to abandon the factory airbox? Any savings there?
Many thanks!

Clb · Oct 19, 2017

There are a few ficm, intercooler threads here,,, check into that.
I would say fab skills will determine cost savings.
I recall there being done around 1k...

saburai · Oct 19, 2017

So if I'm looking at a grand plus plenty of time to get it right, maybe the extra money for the plug and play Hypermax kit would be money well spent...

DougsOBS · Oct 19, 2017

Ill have about 450 in my setup, 6.0 intercooler and homemade copy of the R&D intake. You can do all your piping with silicone angles so minimal welding there. The hard part is the intake manifold. If you have room you can run a carb hat adapter to hook up to the intercooler piping. I didnt so some custom work was needed.

saburai · Oct 19, 2017

Thanks Doug!
I'd love to see some pictures of your set up if you have them. Any interest in fabbing an intake for me?

IDIoit · Oct 19, 2017

with fab work, done my me.
first pic, I spent 4-500 bux.
2nd pic, it would cost me the same-ish.
intake included.

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Clb · Oct 19, 2017

Typo on asmiths system????

HS108 · Oct 19, 2017

I think there is Deff money to made for someone to come up with an idi intercooler kit.

I like hypermax, and if it was 900-1000 bucks I’d buy one, but the 1500 is just a little too rich for me

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FORDF250HDXLT · Oct 19, 2017

I don't weld either but I stilled fabricated my setup.I just lined up the pipes.Drew lines on them with numbers 1 to 1 / 2 to 2 / etc. and took them to a shop.They lined up my marks,drew a few beads and handed them back for like 20 bucks.
You can build your own for under half of $1,500 all easy.It's surprisingly easy.Then you can go Bull Moose and have the performance of OD being what final drive used to be.

The Install Of A FMIC w/ 2nd Gen Banks Wastegated Sidewinder Into 9th Gen Truck

IDIoit · Oct 19, 2017

Clb said:
Typo on asmiths system????

if I was to do his system, and buy all the parts, it would cost me about 4-500 as well.

laserjock · Oct 19, 2017

I think I’ve got like 300 in mine not counting the custom intake hat. It’s priceless. [emoji6]

Cxracing IC0022 (I think)
eBay tubing kit
Elbows
Extra straight pipe piece
IC mounting brackets

It adds up but it’s not hypermax kit territory.

idiTravelAll · Oct 20, 2017

Treadstone makes some good quality reasonably priced intercoolers. I have a TR8C cost me 250 brand new, just sitting in a box.. was going to drop it into my old Audi until I decided it needed to go.. TTs are basically 2 seaters. I'm currently wondering if an intercooler of that size would be efficient in a good ol' IDI

http://edgeautosport.com/treadstone-tr8c-intercooler-500hp/

laserjock · Oct 20, 2017

You are looking for something that flows 750-850 cfm with very little pressure drop. 1-2 psi I think is generally the accepted max pressure drop at the desired flow.

pelky350 · Oct 20, 2017

I've got cx racing cooler ic 022and a universal 2.5 pipe kit and typ4's hat add a couple boots and I'm just over 300$ somewhere. Isn't installed yet but hve 95% of the stuff I need just hvent had time yet to actually do it up. Custom intake would probably be easiest to free up some space. I just used some 3 inch piping and built one at my local discount auto place for pretty cheap+salvage yard parts had laying around

saburai · Oct 20, 2017

Thanks for the input Gents!
It's been awhile since I did any IC research. Does the thermal mass of the IC factor in to a significant degree?
03wr250f said that his Hypermax weights 50#. He might be exaggerating a bit but this got me thinking about the price difference between IC's. Factors are pressure drop, flow, cooling efficiency. What else? Thermal mass? Why the huge price difference between similar (looking) intercoolers?

Intercooler system costs?

saburai

Supporting Member

Clb

Another old truck

saburai

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DougsOBS

Full Access Member

saburai

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IDIoit

MachinistFabricator

Clb

Another old truck

HS108

Diesel Newb

FORDF250HDXLT

The life of an Indian is like the wings of the air

IDIoit

MachinistFabricator

laserjock

Almost there...

idiTravelAll

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laserjock

Almost there...

pelky350

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saburai

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