1st Gen Intercooler Replacement

[RRotzal]

I'd be in for a new one too if you needed more buyers... .

 

[Ncostello]

I don't think they will require multiple units to do this. Once they get one built... they will keep a record so they can build more as needed. They do alot of custom work so one or two isn't a big deal. I did tell them that if they make a nice intercooler for first gens at a reasonable price... they'd have a little niche market on their hands. At least thats what I think.



I'm awaiting an answer on what they'll do. I took mine out and I took photos of how it mounted and what it looks like... and measured it all up. They are going to quote off that. Then if its half way reasonable... I'll send them mine so there won't be any issues with the final product.

 

[300stw]

would like an update, i need 2 coolers...

 

[Ncostello]

I got the reply on 4/28/11. The company is Extreme Turbo Systems of La Center, WA. Michael Roark is the contact. Their main business is turbo race car intercoolers for foreign cars. They also do custom work and have done diesel intercoolers too.



They will build an intercooler (good for 150psi) with all the factory mounting points. The intercooler would have a 3" thick core. OEM thickness is around 1-5/8" thickness. Overall the size would be identical to factory except for the thickness. Thus they would split the difference front-to-back and shorten the inlet/outlet tube length accordingly. This was 2. 5" inlet/outlet. The build also provided "extra thick" core which they use on all diesel intercoolers because of constant pressure variation over a long lifespan.



My job at this point was to determine if I can mount a thicker unit by splitting the difference front-to-back. If that didn't work I guess the extra thickness would be all to the front in relation to the mounting points. I was also going to send them mine for a model to build from as I wouldn't want any mounting issues.



The prices were higher than I a little higher than I expected... but it's still not bad.



If the inlet/outlet pipes are straight off the end tanks (butted up to the tanks) the cost is $670. If they custom fabricate the taper design of the oem inlet/outlet tubes... the cost becomes $780.



I'm thinking a 3" inlet/outlet upgrade might offset not using a taper design, if using the plain inlet/outlet connection at the end tanks... and keep costs lower than building 2. 5" tapered pipes.



Here is a photo of the OEM tube design into the end tank. Thats where the upcharge comes from if you want it.



Having a 3" thick core, and 3" inlet/outlet... I'd think it should flow much more than stock while being the same size. Dare I say nearly good enough for any VE equipped engine?

 

[Ncostello]

ETS - Extreme Turbo Systems - Custom Intercoolers, Intercooler Kits and Performance Parts



This is their homepage. Again they mainly deal with turbo car intercoolers... but the are familiar with diesels too. In my view... any intercooler good for 150psi is fine with me no matter who makes it.



I'm just not sure yet about the 3" thickness if the A/C condenser is mounted too. Grille clearance?

 

[Flexiheep]

I think 3" with A/C will be nearly impossible... . I put a 2000 model year in mine with the factory A/C and it just barely fits behind the grill. I don't believe the 2000 year is a 3" thick core either (inlet/outlet is 3" though), here are a couple pictures to give relative size.



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[Bob Beauchaine]

My Banks Technicooler is 2 1/16" wide and just fits between the AC condenser and the core support. There is room for 3" inlet and 3" outlet which will work better with Tim Worlines 3" SS inlet and outlet piping.



Bob

 

[Ncostello]

Yes... after looking 3" will not work unless I shorten the width and re-design the inlet/outlet to come out parallel with the length... then turn 90 thru the grille support. Only then could I get the AC condenser in between the cooler and the body work. And I couldn't see building a custom fit cooler without having the truck on hand. Hmm. We'll see.

 

[PToombs]

Why not have them recore your cooler? Or recored with larger cores? That's all my PDR IC is. It may be considerably cheaper too.

 

[Ncostello]

I've looked at that too. Who can recore them? I've not found anything searching on the internet. I'm amazed at the lack of availability for one. Banks doesn't offer them any longer. You'd think even though sales was low... they'd keep a few on hand.



If a person had a minor accident and had to get a little body work done and a new intercooler... you'd be up the creek!!! Practically anything else is available, but this thing.

 

[Ncostello]

Still not having any luck finding anybody to build a duplicate sized or recore my intercooler. This is turning out to be way more challenging than I ever expected. Seems the only realistic solution is a 7. 3L fitment/mod. I'm just not too interested in doing that to my stock D250. I want to keep it as-built from the factory as much as I can and not cut the radiator support.

 

[Bob Beauchaine]

Have you tried PDR - Preformance Diesel Research - up in Langly BC. If not give Mark Wilson a call. I seem to remember he had contacts that built inter coolers. Canadian # 604-530-3092 Toll free 866-888-9396.



Bob

 

[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.

Did you call Stoops and get a quote for the Duralite???



Still may be an option for you.



Mike.

 

[rebar]

Im looking for a 1st get intercooler as well as Iv run out of JB weld.

Did anyone find a direct replacement?

 

[RWherley]

I think that 3rd gen cooler will fit if you knock a little off the top and bottom. they should be close to the same width as a 1st gen cooler.

 

[ucidad06]

I got a Banks Stinger kit many years ago and the intercooler is great, try looking up one from them
A 2nd gen might work too

 

[rebar]

I think that 3rd gen cooler will fit if you knock a little off the top and bottom. they should be close to the same width as a 1st gen cooler.

A 3rd gen IC wont fit in my van.. The openings are to low, and my hood latch prevents me from mounting the IC high enough. Iv been wanting a skinny IC from a 09, but I would still have to relocate the openings and not sure about modifying and welding the cast end caps.

I ended up ordering a used 1st gen from a salvage yard and I hope I don't end up with another paper weight.

 

[RWherley]

I have a factory 1st gen cooler but it dose have 2 small leaks in it

 

[DVolk]

call Macs Radaitor in Portland ,Ore they can do it 5037774706