Modding 92 rad support for IC install

[riotwarrior]

I have made the decision to just stick the rusty ole brick nose rad support in for the time being.

It is time I start preparing for a turbo with IC install.

With the above said, I decided to bone the 92-98 rad support, and start to modify it to fit the 6.0L IC I procured.

So the process has begun and without further addo....you guessed it...PICS

Here is the stripped down support with two light cuts on the edges for IC In/OUT tube clearance, notice the foot near the cut on the right!

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Here I point to the other side...I am not differentiating drivers from passengers side at this time in descriptions, this is just L or R in the pictures

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IC now fits into the rad support, there is a difference in location from one side on the IC to the other and diamter as well..

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These end close ups show that there is good clearnce, I feel that doing this OFF the truck allows me to do a very nice job, plus this support needs a little massaging anyway and then some light sandblast and paint, so do the fabbing now!

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Now this shot was to point the IC mounts I will have to fab up. However I did not have the vertical support bar in the middle of the rad support in when I took this picture, that's why the IC is so close to the support at this point. I may go to the wrecker where I got the IC and see if I can cut these parts off or at least take some pictures of them. Pictures would make it so much easier to fabricate for sure and parts would maybe take just a little bit of mods to fit!

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Here is the upper portion of the IC and I sat the vertical support bar in place

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Here are a couple of side shots with that vertical bar in place!

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Over all I think this will work extremely well. The down side at this time, HEADLIGHT bar...but that...is another fab article!

Al

 

[icanfixall]

It looks simple with all the pics... Somehow I just can't get started on my hypermax installation.. I'm so lazy....

 

['94IDITurbo7.3]

Gary, c'mon man. Mel even has a step-by-step in the tech articles for the h-max IC.

 

[icanfixall]

The actual intercooler install is not the issue. Its adapting the hat to the Banks wastegated turbo I have. Got to modify the hat to clear the compresser and clock the turbo outlet side a bit. Nothing simple for me ever...

 

[riotwarrior]

The actual intercooler install is not the issue. Its adapting the hat to the Banks wastegated turbo I have. Got to modify the hat to clear the compresser and clock the turbo outlet side a bit. Nothing simple for me ever...

That's gonna be a problem in any NON IC turbo install anyway. Adapting something to fit that was never designed originally to work with an IC is probably one of the more difficult issues.

One more thing, fabbing this up OFF the truck will make it much easier. The biggest hurdles, are the actual RAD interference on the edges, to be checked in a few days and then the worst part, getting headlight header/bar to function, and a grill to cover it all.

The grill will be a TOP SECRET project, TBA once completed and ya'll will likely be all over yerselves if it turns out as well as I imagine it should look!

 

[riotwarrior]

Ya....so small update...not much...gotta really thunk this through before I GO an CUT more... or...Or...OR...cut and hope for best. I will see if I can figure out something..angle outlets on IC...etc but these pics depict where I theoretically have to cut the rad mounts and thus loose strength...

Notice the red paint marker on the rad mounts

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Here is a small section that needs some massaging...work etc...

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and a lil massage needed here too....clearly there is work

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Overall you can tell that there is going to be issues with fittment. I'll deal with those shortly enough as best I can...be it build some lower support that reaches up onto the actual rad support...I'll have to see what I can think of.

So for now...nuff done!

 

[riotwarrior]

K yesterday was looking at the white rhino and the brick nose rad support and how close it is to the winch on the front. It would appear to me that adding the OBS front clip is going to force me to change up the winch mount something fierce! Whatcha all think...enough room...NOT...that's my old lower rad hose from the wide short rad I used for size comparison.

Here one can see the top portion of the rad support and how there is insufficient clearance for an IC

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clearly this is too tight...hmmm....OK I can re do this mount I never liked it to begin with!

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Ya...add the IC and I'll be bashing the IC and winch motor for sure with the OBS support...hmmm

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[gdhillon]

how heavy is that rad support?

btw lookin good as always Al.....im gonna have to get you to give me fabbing 101 when we have the BC rally