intercooler setup/fabrication

[Dave7.3]

Excellent reading concerning intercoolers in this thread!

As far as proof with what an intercooler can do, this quick video sums it up perfectly:
http://www.youtube.com/watch?v=nf7ladNL7V8

Keep in mind, yes that is a PSD running a quite bit more PSI than we normally put out, but the temperature difference before/after the intercooler is jaw dropping! Denser air = more power.

Now about the various kits out there for us... Yes, there is an ATS kit as well as a kit produced by Hypermax. From what I have heard from others, ATS is less than helpful when it comes to supporting/selling products for our old IDIs. Something to do with phasing out obsolete hardware.
On a better note, Hypermax to my knowledge still does support their kits for us with no plans to phase them out in the future. BOTH of these kits however run over a thousand dollars!

For the reason of the very high cost, most turn to the ricer aftermarket that practically throws "universal" kits out the door for $250-$400. Do a search in the forums and you will find a handful of ebay links with kits that others have used.

Now you must be wondering...why the heck would you use that dinky 4 cylinder intercooler kit for this BIG V8 diesel!?
Simple, our trucks don't usually run high boost pressure like the powerstrokes do (~15psi vs upwards of 30+ psi). With that difference in mind, why would you stick that monster intercooler that is designed for 30+ psi cooling on a PSD on the front of an IDI that may only see half of that?

Further proof you ask? Take a look at the kits actually designed for the IDI from ATS/Hypermax. They aren't anywhere NEAR as large as the PSD either!

If you can handle a little fabrication, save yourself some cash and boost your efficiency with an intercooler that suits the demand of your IDI. You won't regret it!

 

[War Wagon]

Everthing on here is good info and discussion. I thought the same thing of the PSD IC possibly being too large due to the fact that it was designed for higher boost pressures. I am still trying to understand all the science of the intercooler theroey. I haven't made a decision yet, but I always feel curious to do something different and experience the results for myself.

 

[84TD]

Has anyone ever experimented with flexible hose for the piping?

Like this
http://superflex.thomasnet.com/item...products-/flexible-liquid-tight-conduit/8436?

Also I have a ATS kit, I have been thinking I want to do an intercooler but I dont know what to do about the hat, I could machine something the same size as the turbo outlet and insert it. The ATS hat just has a tight fitting 0ring to seal the turbo out.

Great thread!

 

[rhkcommander]

Low temp threshold and 2" size max would have me saying no. Among other reasons

 

[typ4]

Flex hose will not work. I do have an intake hat setup that I build, pics on here somewhere.

And war wagon, if you buy banks parts , just remember you are helping pay for all those pretty pages in the front of Diesel Power.

I can tell you super duperIC effiecency is not really needed on these engines, the temp drop of any IC will help, I ran a 6.0 IC for a while now have a cut down 7.3, no difference except I have more air across the top of my radiator.

Spend your money on good usable parts and keep it in the small businesses.
Towcats truck runs good and he didnt drive mine loaded but he can tel you how it runs, I threw him the keys and said " flog it".

He was smiling as I recall when he got back

Lag is not nearly as critical on a diesel as a gasser. once the tubes are "full" power will be there.

 

[War Wagon]

A stock 7.3L PSD will not push much over 15 psi that I have seen. I would think an IC designed for a PSD would work well for a modded IDI 7.3L that might realistically push 15 psi.

 

[Dave7.3]

A stock 7.3L PSD will not push much over 15 psi that I have seen. I would think an IC designed for a PSD would work well for a modded IDI 7.3L that might realistically push 15 psi.

Stock maybe, but the IC system on the PSD is designed to handle quite a bit more than that. Thus, guys are able to push ~30 psi without touching the IC system.

 

[War Wagon]

Checked with ATS for the rest of there kit and they do not offer it anymore. Banks will not sell individual pieces only complete kits.

 

[ocnorb]

I have an ATS hat in my possession that I have been looking at copying/improving. The hood clearance on my '57 is about 16" so my thought was to build an elbow with a longer smoother sweep.

While I'm doing it, making another copy for a few friends will happen.

Its mostly a matter of getting the free time to get some made.

Going to Moab this weekend!

 

[War Wagon]

If I used a intercooler with 3" inlet/outlet I am thinking I would be best off to buy reducer boots and run 2.5" piping. My turbo out let is what? 2.25 maybe 2.5. The OD of my ATS intake hat is 2.5. I can't imagine there would be any benifit from running 3" pipes on this engine, especially since it is smaller running out of the turbo and going into the engine.

Can the ATS hat be clocked to any position for a custom setup? I haven't looked at it close.

 

[84TD]

The hat can be moved and so can the turbo outlet, although I am not sure how exactly. But I have seen it in pics on this forum.

I was wondering about the tubes, since the ID of the turbo and the hat are close to 2in I was actually thinking of running 2in pipe to the intercooler. My theory is that less boost will be lost.

Also in my 77 I have more than normal room inbetween my ran and the radiator, almost 4in, I was thinking of doing a big flat IC like out od a duramax and puting it in the engine bay behind the rad, good idea?

 

[War Wagon]

Lots of intercoolers on ebay. Anywhere from 350 to 800 CFM. Some don't specify. What is a good size for these enginges? What CFM are the ATS and Hypermax versions?