Let's Talk Intercoolers

[War Wagon]

Got my intercooler in, The seller sent 3inch boots, I was planning on using 2.5 inch pipe. Will it boost slower with 3 inch pipe??

I debated this question for my intercooler too. I'm using a Banks Technicooler for a 94-97 7.3L PSD. It has 3" in/out and is intended to be used with 3" tubing. I have a hard time seeing how the engine could benifit form tubing that is considerably bigger than the outlet of the turbo and bigger than the inlet of the intake horn. The Banks kits for various models seem to stress the fact that they use larger smooth flowing piping for less restriction. This is there claim anyway. ex: 6.0 kit upgrades from 3" piping to 3.5" with the new intercooler being 3.5" in and out. I should do the math on the bigger diameter of pipes.

Let's say that the nessisary piping is 8ft(96") long total. The volume of just the pipng would be:
2.25" = 1.125 x 1.125 x 3.14 x 96 = 382 cubic inches
2.5" = 1.25 x 1.25 x 3.14 x 96 = 471 cubic inches
3" = 1.5 x 1.5 x 3.14 x 96 = 678 cubic inches

Food for thought I guess. About 110 more for 2.25 to 2.5. About 200 more from 2.5 to 3. I have a hard time understanding how it would benifit choking 3" back down to go into the intake horn, unless you had a bigger intake horn. I would think that necking the diameter back down would cause a resriction and be counter productive and out weigh the the benifit of the larger 3" pipe.

I plan on using 2.5 pipe but I would have to build and try 3 to know if there is a noticable difference.

 

[snaponprofile]

I got my intercooler piped.....finally!! I used a 7.3 PSD intercooler and used 2.5 inch aluminum pipe. I got everything from silicone intakes for $170. My bro who welds aluminum welded it up. I just have two hump hoses connecting each of the pipes in the middle for ease of installation/removal. I will post better pics when I grind the weld and bleand them, this is just rough for now but you can see the plumbing....

Enjoy!

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[towcat]

nice work!

 

[rjjp]

I have a hard time understanding how it would benifit choking 3" back down to go into the intake horn, unless you had a bigger intake horn. I would think that necking the diameter back down would cause a resriction and be counter productive and out weigh the the benifit of the larger 3" pipe.

Would loose pressure and increase velocity, in theory.

Question, I've been noticing that some of yall have vacuum pumps on top of the engine by the a/c compressor, I'm guessin this is for the serpentine setup. How would one go about gathering the parts to convert to a serpentine setup?

Hijack over.

Yes it's for the serpentine setup, best bet is scrap yard.

 

[snaponprofile]

Just hooked it all up and am getting 7 psi empty, before I got to 10psi. Gate is at 13-14psi. It really goes now, feels better and I haven't even touched the fuel! Finished product......

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[towcat]

you are going to love the throttle response now
my truck used to drop off at 3k rpms. now it swings hard into the governor.
it's going to be like....wow...I didn't think there was power up there...

 

[snaponprofile]

you are going to love the throttle response now
my truck used to drop off at 3k rpms. now it swings hard into the governor.
it's going to be like....wow...I didn't think there was power up there...

Already drove it and there is quite a difference, my rmp's do go up higher now too. Its so cool(get it) to open the hood and touch the hot side and then the cold side and know that your engine used to be getting hot air, but now it is getting cold air.

I can't wait to see how it runs with the fuel up.

 

[88 Ford]

Already drove it and there is quite a difference, my rmp's do go up higher now too. Its so cool(get it) to open the hood and touch the hot side and then the cold side and know that your engine used to be getting hot air, but now it is getting cold air.

I can't wait to see how it runs with the fuel up.

What is your target boost level after you increase your fuel? And do you think you'll have to mess with your wastegate to get it to the boost level you were at originally?

 

[Black dawg]

Just hooked it all up and am getting 7 psi empty, before I got to 10psi. Gate is at 13-14psi. It really goes now, feels better and I haven't even touched the fuel! Finished product......

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looks really good.

 

[FORDF250HDXLT]

I just paid $50 for a Serp Belt. The'd buy a lot of V's... just sayin

you'll be good for 100k miles or more now... just sayin.

 

[phazertwo]

Just hooked it all up and am getting 7 psi empty, before I got to 10psi. Gate is at 13-14psi. It really goes now, feels better and I haven't even touched the fuel! Finished product......

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That's f'ing HOT! I really want a IC. My truck falls on its face when I get in the big hills trying to pull the trailer. Have to keep it at about 3k in 3rd to keep it moving, and on the BIG hills its 2nd. Would LOVE to be able to hold on to the power up in the higher RPMs!

PZ

 

[88 Ford]

Dude my intercooler is like night and day also. It is a worthwhile upgrade.

 

[War Wagon]

Nice. Glad you like it. I need to get to work on mine.

 

[snaponprofile]

Sorry, I noticed the pic is missing, here it is again.

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[Donsbad89]

snaponprofile - what intercooler did you use and did you have to cut on the rad support? Do you have any pics of the intercooler?