bike-maker
Full Access Member
Been busy with work and other projects for the last year or so, haven't spent much time tinkering on the truck. But lately I've been getting the itch and collecting some parts, so here goes with the next project; an intercooler.
I've seen a few different people wanting to see a intercooler installed in a AC equipped slant nose, which my truck is.
But let me start by saying, that between the intercooler, the york pump I just picked up for an on board air setup, and the fact that the truck never has had working AC, I finally made the executive decision to delete the AC system and be done with it. From what I now know, it's kind of a pain to fit just an intercooler in there, let a lone an AC condensor as well. Only other intercooler equipped slantnose truck I remember seeing was Mel's Moose truck, but he used a different IC and has that low, wide radiator.
So I went down to the local JY and picked up a factory aluminum intercooler off of a 2000 Superduty; $100, and it was already pulled and on the shelf. The Superduty IC is the same width as the IDI tall/narrow radiator, and about 6" shorter (rough guesstimate). The placement that made the most sense was to drop the IC down so the bottom of it was even with the bottom of the radiator. This lined up the 2 holes underneath the radiator mounting brackets for the tubes to pass through the core support. Any higher, and the radiator mounting would have to be reworked.
While pulling the front end apart, it looked like there was going to be plenty of room, but after getting into it a little more, I realized that the intercooler can't just bolt to the front of the core support, I had to actually recess it into the core support.
So here's before I started breaking out the tools of destruction.
Here's the mounting on the unmolested IC
And here's after I got it to fit
Bottom mounts are now gone, they were running into the core support big time.
Top mounts got chopped in 3 directions.
For those wondering about the bottom mounts, believe me when I say that once the whole mess is wedged in place, it's not going anywhere.
Here's what the core support looked like once the sparks were done flying.
I'm hoping the lighter weight of the aluminum Champion radiator will offset all of the beef I took out of the core support.
I even had to take about a 1/2" chunk off of the backside of the support (engine side) to get sufficient clearance around the tubes.
Also had to chop some of the flange off the radiator - bottom mounts for the fan shroud are now gone, but they could be relocated higher pretty easily. I've got a Windstar fan setup sitting in the garage to try out, but that will be another thread in the not so distant future...
You'll also notice I had to ditch the stock bolts and clippydoos for the bottom 2 radiator mounting bolts. Threw some 3/8" carriage bolts in their place. There wasn't even enough room between the carriage bolt heads and IC to run a regular bolt head.
The IC just barely sits back in there; how close is it? I'd say about 1 RCH. It clears, but not by much.
Here's after I bolted the piece on that all the grill and hood latch attaches to.
You can see a piece of neoprene sheeting that I have wedged between it and the IC; there's a couple more pieces between the IC and radiator. Between the neoprene chunks, and the hard rubber weather stripping that is on the backside of the IC to seal it to the radiator, the IC is completely wedged in place. Then I drilled through what was left of the stock tabs up on top of the IC and drilled/bolted through the radiator mounting brackets.
Here's a pic showing the clearance between the IC and the back of the grill - only about 1/2"
The sheet metal piece that sits below the grill and behind and above the bumper has about the same amount of clearance.Adding a AC condensor to the stack would push the IC another 1-1/2 to 2" closer to the grill. I'm not saying it's impossible to put a intercooler on a AC equipped slant nose, but it would require some pretty extensive surgery.
And here she is all put back together.
So for the next guy that takes on this project, my recommendation would be to use a different IC. I've heard some argue that the PSD IC is on the big side of what we need, and having one just a few inches shorter would have made life much easier.
As it sits, almost 1/2 of the IC is covered by the front bumper. This might counteract the IC being too big (if it even is), but I'll probably try to fab some kind of air scoop for it in the future.
So that's it for part 1. Part 2 will be running the tubing. I'm figuring on running 2-1/2" steel tubing (cause I can weld it right here in my garage).
And now a question; I have an ATS 085 turbo (pretty much the same as a 088 except for the airbox, which I ditched anyway). What have others done for the hat that goes on the intake? It's looking like I'll just have to build my own. I spent about an hour trying to wrestle the one off of my truck today, but it's looking like the turbo has to come out to get the blasted thing out of there. Guess I'll try sealing that stupid slip joint for the up pipe from the top this time....
I've seen a few different people wanting to see a intercooler installed in a AC equipped slant nose, which my truck is.
But let me start by saying, that between the intercooler, the york pump I just picked up for an on board air setup, and the fact that the truck never has had working AC, I finally made the executive decision to delete the AC system and be done with it. From what I now know, it's kind of a pain to fit just an intercooler in there, let a lone an AC condensor as well. Only other intercooler equipped slantnose truck I remember seeing was Mel's Moose truck, but he used a different IC and has that low, wide radiator.
So I went down to the local JY and picked up a factory aluminum intercooler off of a 2000 Superduty; $100, and it was already pulled and on the shelf. The Superduty IC is the same width as the IDI tall/narrow radiator, and about 6" shorter (rough guesstimate). The placement that made the most sense was to drop the IC down so the bottom of it was even with the bottom of the radiator. This lined up the 2 holes underneath the radiator mounting brackets for the tubes to pass through the core support. Any higher, and the radiator mounting would have to be reworked.
While pulling the front end apart, it looked like there was going to be plenty of room, but after getting into it a little more, I realized that the intercooler can't just bolt to the front of the core support, I had to actually recess it into the core support.
So here's before I started breaking out the tools of destruction.
You must be registered for see images attach
Here's the mounting on the unmolested IC
You must be registered for see images attach
And here's after I got it to fit
You must be registered for see images attach
Bottom mounts are now gone, they were running into the core support big time.
Top mounts got chopped in 3 directions.
For those wondering about the bottom mounts, believe me when I say that once the whole mess is wedged in place, it's not going anywhere.
Here's what the core support looked like once the sparks were done flying.
You must be registered for see images attach
I'm hoping the lighter weight of the aluminum Champion radiator will offset all of the beef I took out of the core support.
I even had to take about a 1/2" chunk off of the backside of the support (engine side) to get sufficient clearance around the tubes.
Also had to chop some of the flange off the radiator - bottom mounts for the fan shroud are now gone, but they could be relocated higher pretty easily. I've got a Windstar fan setup sitting in the garage to try out, but that will be another thread in the not so distant future...
You'll also notice I had to ditch the stock bolts and clippydoos for the bottom 2 radiator mounting bolts. Threw some 3/8" carriage bolts in their place. There wasn't even enough room between the carriage bolt heads and IC to run a regular bolt head.
The IC just barely sits back in there; how close is it? I'd say about 1 RCH. It clears, but not by much.
You must be registered for see images attach
Here's after I bolted the piece on that all the grill and hood latch attaches to.
You must be registered for see images attach
You can see a piece of neoprene sheeting that I have wedged between it and the IC; there's a couple more pieces between the IC and radiator. Between the neoprene chunks, and the hard rubber weather stripping that is on the backside of the IC to seal it to the radiator, the IC is completely wedged in place. Then I drilled through what was left of the stock tabs up on top of the IC and drilled/bolted through the radiator mounting brackets.
Here's a pic showing the clearance between the IC and the back of the grill - only about 1/2"
You must be registered for see images attach
The sheet metal piece that sits below the grill and behind and above the bumper has about the same amount of clearance.Adding a AC condensor to the stack would push the IC another 1-1/2 to 2" closer to the grill. I'm not saying it's impossible to put a intercooler on a AC equipped slant nose, but it would require some pretty extensive surgery.
And here she is all put back together.
You must be registered for see images attach
So for the next guy that takes on this project, my recommendation would be to use a different IC. I've heard some argue that the PSD IC is on the big side of what we need, and having one just a few inches shorter would have made life much easier.
As it sits, almost 1/2 of the IC is covered by the front bumper. This might counteract the IC being too big (if it even is), but I'll probably try to fab some kind of air scoop for it in the future.
So that's it for part 1. Part 2 will be running the tubing. I'm figuring on running 2-1/2" steel tubing (cause I can weld it right here in my garage).
And now a question; I have an ATS 085 turbo (pretty much the same as a 088 except for the airbox, which I ditched anyway). What have others done for the hat that goes on the intake? It's looking like I'll just have to build my own. I spent about an hour trying to wrestle the one off of my truck today, but it's looking like the turbo has to come out to get the blasted thing out of there. Guess I'll try sealing that stupid slip joint for the up pipe from the top this time....