Trainmaker
Registered User
[/ATTACH]Hi everyone, first post so be patient. I wanna share my opportunity to install an intercooler in my 1992 F250. Now I have many years of fabrication experience and welding so this might not be for everyone but it is an option that worked well for me.
I read many of the posts on here and looked at pics for many hrs, but just didn't wanna cut holes in my radiator support and hafta deal with reaching way down inside to tighten or undo the clamps. So here we go. I have a Banks Sidewinder that had the huge box on top, what a pain to deal with, so as I wanted an intercooler I also wanted easy access to the engine components. I started with looking for an alternative routing without a lot o bends, outside of the radiator was an option, so I started mapping and planning, pert simple actually, pressure side of the turbo to the driver side and intake side to the passenger side. I did try some other configurations but stuck with this, then I bought a cooler out of a '99 Super Duty and a 2 1/2" tubing kit from Ebay with straights, 90s, 45s, and couplings for about $100, and a few extra couplings. I cut the inlet and outlet off the cooler and welded them closed. Next I used some straight pieces from the kit and welded them at a slight angle, after hacking up the outsides of the cooler, up behind the grill in front of the radiator support. Some trimming on the grille support had to take place for the cooler to fit and the tubes to protrude thru the top. The cooler fits in from the top so I didn't have to remove the bumper, just simple angle iron mounts that the factory cooler mounts fit on, I also made my own intake hat for the manifold opening with a spot for the boost guage, I did smooth it out after the photo op. I did hafta take some material out of the hood to clear the radius going over the rad support. I also added temp sensors in the tubing for compressor side and intake side of the IC, intake normally runs 10 to 15 degrees above ambient. I have more pics available, holler at me if you want to see more. Now I am up for ideas on a way to make a ram air hood/filter assembly, pvc is not real classy but it works for now. Thanx guys, hope you enjoy and catch some ideas for your own projects.
I read many of the posts on here and looked at pics for many hrs, but just didn't wanna cut holes in my radiator support and hafta deal with reaching way down inside to tighten or undo the clamps. So here we go. I have a Banks Sidewinder that had the huge box on top, what a pain to deal with, so as I wanted an intercooler I also wanted easy access to the engine components. I started with looking for an alternative routing without a lot o bends, outside of the radiator was an option, so I started mapping and planning, pert simple actually, pressure side of the turbo to the driver side and intake side to the passenger side. I did try some other configurations but stuck with this, then I bought a cooler out of a '99 Super Duty and a 2 1/2" tubing kit from Ebay with straights, 90s, 45s, and couplings for about $100, and a few extra couplings. I cut the inlet and outlet off the cooler and welded them closed. Next I used some straight pieces from the kit and welded them at a slight angle, after hacking up the outsides of the cooler, up behind the grill in front of the radiator support. Some trimming on the grille support had to take place for the cooler to fit and the tubes to protrude thru the top. The cooler fits in from the top so I didn't have to remove the bumper, just simple angle iron mounts that the factory cooler mounts fit on, I also made my own intake hat for the manifold opening with a spot for the boost guage, I did smooth it out after the photo op. I did hafta take some material out of the hood to clear the radius going over the rad support. I also added temp sensors in the tubing for compressor side and intake side of the IC, intake normally runs 10 to 15 degrees above ambient. I have more pics available, holler at me if you want to see more. Now I am up for ideas on a way to make a ram air hood/filter assembly, pvc is not real classy but it works for now. Thanx guys, hope you enjoy and catch some ideas for your own projects.
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