1st Gen Intercooler Replacement

[Ncostello]

I've read Piers and New Era has 1st gen replacement intercoolers. But Piers site doesn't list one, and New Era doesn't list any intercoolers for anything.



I need a new intercooler. Unless I'm wrong... I find it rediculous that I can't seem to just find one and buy it. There are people making them for every model of diesel out there, and people making them for tuner cars that never even came with a turbo in the first place... but I can't find one for my 1st gen that had one originally.



Besides that... it seems $1000 is a low number for ANY aftermarket diesel pickup intercooler.



What's so special about an intercooler that it costs 3x more than a custom built 4 row aluminum radiator?



It seems like I can replace everything made of metal on my truck without too much fuss... . except the darn intercooler. What gives?



All I can think of is pay a fortune to have a custom built one made by ????

 

[Simplysmn]

You can also use a Power stroke ford innercooler I believe the 7. 3 one is the 1 you want it's a upgrade from stock .

 

[Ncostello]

I've read that. But I was concerned because I still have to mount the A/C condenser and didn't really want to modify my sheetmetal... as I'm trying to preserve the truck in its stock condition. But I'll look into that if all else fails.



I've found some custom builders that show some VERY amazing work for racing and custom cars. Hopefully one might respond and build one for me.

 

[mwilson]

I've read Piers and New Era has 1st gen replacement intercoolers. But Piers site doesn't list one, and New Era doesn't list any intercoolers for anything.



I need a new intercooler. Unless I'm wrong... I find it rediculous that I can't seem to just find one and buy it. There are people making them for every model of diesel out there, and people making them for tuner cars that never even came with a turbo in the first place... but I can't find one for my 1st gen that had one originally.



Besides that... it seems $1000 is a low number for ANY aftermarket diesel pickup intercooler.



What's so special about an intercooler that it costs 3x more than a custom built 4 row aluminum radiator?



It seems like I can replace everything made of metal on my truck without too much fuss... . except the darn intercooler. What gives?



All I can think of is pay a fortune to have a custom built one made by ????

Is there a part number on yours somewhere or do you have the Dodge Part Number handy???



There is a company in Calgary, Alberta that makes charge air coolers called Dura-Lite and they are marketed through NA Daimler Truck Dealers. They are a fantastic, well manufactured product with a 7 year / 1,000,000 mile warranty. That is no joke, and so far I have had only one fail at 3 years of age in a Logging truck application and they took care of the failure in a prompt fashion.



Nice company that builds a good product and will stand behind it.



If you would like me to check out possible pricing and application just let me know. If you can't find a part number don't sweat it, just provide all the detail you can about the pick-up and I will call one of the engineers up there. I am almost 100% that they cover the Diesel Pick-Up market.



Link to the home page here.

Dura-Liteâ„¢ Products, Dura-Liteâ„¢ Heat Transfer Products Ltd, Radiators, Charge Air Coolers,



Mike.

 

[HHhuntitall]

I'd call Piers or Banks and see what they have. A lot of the older 1st gen stuff is not listed in their catalogs as it's discontinued, but it's still in stock. Or find a dealer that has it, like these guys... ... . Banks Techni-Cooler Intercooler Assembly: 91-93 Dodge 12-valve Cummins 5. 9L (Factory-Intercooled)

 

[mwilson]

Just called Dura-Lite and spoke with an engineer. (Looked at your sig and saw what you had for a truck... )

He found his notations on the first gen Dodges, '91-'93 and they do make one to fit.

Part Number at a FTL dealer would be DHT DO70A.

They are a direct ship item which means that a dealer has to buy 12 of any number to get free inbound freight.

Call Stoops and see how they would use you, they probably do buy them 12 at a time, to give you some reference I would charge about $900. 00 for it.



I can't stress how well built these things are. As soon as my customers are off the Freightliner warranty coverage I sell these coolers as replacements rather than the OEM coolers.



Mike.

 

[Ncostello]

Thanks all. I'll check into all these options. This is about the only thing on this truck that has caused me frustration. Everything else is easy!

 

[Shadrach]

I've sold Dura-lite for years and had no problems with them. We put one in my buddies 93 W350. Shadrach

 

[HHhuntitall]

I've sold Dura-lite for years and had no problems with them. We put one in my buddies 93 W350. Shadrach

If you don't mind my asking, what did that cost?

 

[DVolk]

call any good radaitor shop any they can get one for you or build one or search a good bone yard

 

[PToombs]

If you call PDR ask for Mark Wilson, or you can PM NascarMark on here. He was doing them himself, thru PDR. Nobody else there had a clue when I called, then I did some searching and found he was the contact. I got mine in '05, and it was $700 then. I can't compare it to stock, as mine was like cheesecloth. I do know the cross tubes are about 3 times the size of stock.

 

[Ncostello]

Being the same size... that should flow much better, yes? Did it have the condenser mounting provisions?

 

[PToombs]

Yes, it flows much better than stock. As for the condensor mounts, I'm not sure as I don't have one. They were using stock cooler ends and putting a new core in them, so I think they would be on there.

 

[Bob Beauchaine]

In 2003 I had my OEM charge air intercooler replaced with a Banks Technicooler. I had the work done because I wanted my A/C serviced and that needed to be removed to install the I/C. The Banks unit flows much better and is larger than the OEM unit. The A/C condenser sits about 1/8 of an inch in front of the I/C and was not a problem to install with the Banks unit.



A few years later I also installed Tim Worlines replacement inlet/outlet SS pipes. Boost dropped about 2psi but I expected that. The only place I can get egts over 1000 degrees is on a dyno. Running up Cabbage Hill east of Pendelton OR max egts will not go over 950 in 5th gear.



I still have the OEM I/C.



Bob

 

[Ncostello]

What working PSI should a custom builder shoot for in a 1st gen? I'm thinking a cooler that works in the 30's should suffice most 1st gen trucks. But I know little about what modified trucks see with improved turbocharging and injectors.



I have a custom builder interested in making me one that fits just like OEM, perhaps slightly taller, and with 3" inlet/outlet. Until I upgrade turbos/pipes... I could just get aftermarket 2. 5" to 3" adapter boots. Or he'll make with 2. 5" inlet/outlet. My choice. I told him I'd handle mounting the condenser to the radiator support using my own custom fabbed brackets (I can handle that) instead of directly to the intercooler. It would make his job a little easier, and give the intercooler a break. Fabbed end tanks may not like holding the intercooler as well as cast tanks. The price appears to be in the high 300 to mid 400 range.

 

[JLEONARD]

What working PSI should a custom builder shoot for in a 1st gen? I'm thinking a cooler that works in the 30's should suffice most 1st gen trucks

I would say 60 psi working pressure would suffice.

You want some safety factor.

I would go with the 3 inch and use adapters

 

[Bob Beauchaine]

I,ve got to agree with Jay - at least 60 psi. I,m only running a modified HX35 and I see numbers close to 40 psi at WOT.



Bob

 

[Ncostello]

It seems it'll be a non issue. The cores they use are rated for 150psi... they are the type you'd find on a mobile air compresser application. Their race cars run 50psi and all cores are pressure checked with 30psi after final welding is complete.



In all it sounds like a good deal and I'm hoping it works out. I'm going to approach them about perhaps being a source for other 1st gen owners who may need a replacement. Kinda like a little niche maybe. They already do very well with race car intercoolers. I'll give them my old one so they'll have something to look at for future reference.



It's not like they'd have to invest anything really, nor would they need any inventory. At least someone willing to build them at a reasonable cost... thats about all we need.

 

[Ncostello]

Here is a photo of one they built for a turbo charged car. I'd love to have something like that on my Dodge.

 

[ENafziger]

In all it sounds like a good deal and I'm hoping it works out. I'm going to approach them about perhaps being a source for other 1st gen owners who may need a replacement. Kinda like a little niche maybe. They already do very well with race car intercoolers. I'll give them my old one so they'll have something to look at for future reference.

I'd like to see how yours turns out! For the $450 range, I'd be interested.

Thanks, Eric