Intercooler upgrade

[THuebner]

Hi Everybody,

I noticed in the latest magazine (TDR Issue 50) on page 22 RWWinslow indicated different part numbers for fan hub bearings depending on whether or not the engine was intercooled.

I have an opportunity to buy a 1st gen. intercooler for $200. 00. I would like to do the upgrade but wonder exactly what would be required to properly change the engine from non-intercooled to intercooled.

If anyone out there has done a sucessful conversion or has a list of parts that would be required to convert I would appreciate hearing from you.

Thank you.

Tom

 

[BJMarshall]

Check out my gallery. Few pics there of when I did my swap. Pretty simple.

 

[THuebner]

Hi BJ,

Thanks for the comeback. excellent pictures of your conversion. If understanding the caption for one of the pictures is correct, you had to install a new throttle bracket and new fuel lines to accomodate the new air intake, is that correct?

Tom

 

[BJMarshall]

I used the nonIC fuel lines, but had to move them just a little. I can't remember right now why I changed the throttle bracket, but I'm sure something wouldn't clear with the old one.

 

[THuebner]

Hi BJ,

Thanks for the reply. OK once I have the intercooler and pipes it sounds like the other needed components from an intercooled truck are the throttle bracket, radiator and shroud. I think I can do this. I wonder why the fan hub bearing (and fan hub?) are different between the intercooled and non intercooled. The point is, I'm sure that not every change that was made at the factory between the earlier non intercooled and later intercooled trucks is necessary for a working conversion.

Tom

 

[BJMarshall]

Tom,The reason for the different fan drive is because of the switch in radiator and fan shroud. The aftercooled trucks have a crossflow radiator while the earlier ones are vertical. The fan shroud is different for this radiator as well as the fan placement. If you're just putting on the intercooler without everything else, plan on a little fabrication work.

 

[THuebner]

Hi BJ,

Thanks, I appreciate your patience. If the fan, hub, and hub bearing from an intercooled truck are needed for a proper conversion I certainly would not mind installing them. I'm not trying to do this cheap, I would like to do it right. Hence the question in my original post, that is, what parts are needed to properly convert from non-intercooled to intercooled?

Tom

 

[BJMarshall]

OK. Here's my best shot at a list.

Intercooler and ducting

Radiator

Core support

Fan Shroud

Fan

Fan drive

Belt

Throttle cable bracket

A/C lines and condensor

Plan on rerouting the grid heater wires out so they will reach

Injector lines have to be moved a little.

Intake plate needs to be turned around.

If you want it to look exactly as an one looked from the factory, you will need to change the fuel lines as well.

If all you have is the Intercooler and nothing else and you want to do this, cut holes in your core support and fabricate mounts for the IC, then fabricate ductwork to get the air in and out of the IC.

Also forgot to add you will need the compressor housing and wheel from an intercooled truck along with the elbow. This will also necessitate a 4" intake hose since the one on the NonIC trucks is 3".

 

[THuebner]

Hi BJ,

Thanks so much for your patience. It was very nice of you to list all those parts and the steps needed for the conversion. As you noted all I have right now is access to a good used intercooler. Obviously the best thing will be to obtain an intercooled truck that can be canibalized for the needed parts. You give the impression that the performance jump you noticed was significant enough to make converting worthwhile. I'll have to see if I can locate a doner truck. As with anything else all it takes is time and money.

Thank you for taking the time to help.

Tom