Larger Intercooler

[DanaLittle]

I just installed a larger intercooler in my 1993 w250 just for fun. My Dad upgraded his 99 powerstroke intercooler so i took his old one and put it in. The i/c was a fairly easy install. I only had to cut about a 1in wider opening where the tubes go through core support. The intercooler is 18in tall , stock is 12. 75in tall, the thickness is 2in on powerstroke, 1 5/8 on stock, powerstroke has 3in inlet and outlet. Stock has 2. 5. I still had room to keep the a/c. The only thing i had to remove was the small transmission cooler but i have the underbed one. Also added a newer intake and larger i/c tubes. I haven't done any real driving to see what egts have done hopefully this weekend.

 

[OKish]

wow, nice install. im definately saving this page.

 

[Sri Ram]

yeah, good job. Tell us about the new compressor housing and intake horn…

 

[DanaLittle]

the new compressor housing is a stage 3 housing and wheel from gillett diesel service cheaper than HTT same parts. The intake horn is off a 2001 or 2 not sure. I stopped by Diesel power products to get new i/c hoses and they had the intercooler and piping and horn laying on the floor of shop from a takeoff and I told them I would like to try it. I used all piping had to cut it down to make it work but it turned out good. The intake horn is a lot bigger than the stock one and since I used the larger piping I used it. I had planned to leave my 93 stock but you know how that goes. Next is the injectors I bought from New ERA Diesel edm's . They had a group buy on them a while back. Pretty soon I will have to think about upgrading the auto transmission.

 

[bgilbert]

Awesome. Wish I could find some Ford parts like that.

 

[DanaLittle]

I had a chance to take the truck on a drive today to check egt's. With the A/C on idling on 90 deg day egt's used to be 325 now just under 300. On a full out run I used to top out at 1100 now I could just get past 900 at 80mph. Looks like I need to put my new injectors in and see what i will do with more fuel. Looks like it was a good swap it only took about 4hrs of work.

 

[JSpecht]

Could you tell a real differance from stock housing to the after market on ??? Do you think it was worth the money??? what exhaust housing size ar you running???

 

[DanaLittle]

I didn't notice a big differance. I picked upsome boost how much I'm not sure it pegs my 30lb gauge so i at least picked up 3-4lbs of boost. Wasit worth the money? I say yes if for nothing other then the sound it makes now but I'm sure it's putting cooler air in.

 

[Chris and Sam]

Wow, that looks stock, and a good fit too... ... .

 

[matches]

First of all, Ebay has several of these intercoolers for around $100. 00. Where the new numbers taken just off of the intercooler install, or was the turbo done at the same time? I'm intersested in doing the switch to the bigger intercooler, intake horn, but just wondering how much it will help?

 

[DanaLittle]

The EGT numbers were after the I/C install only. I put the compressor housing and wheel on about a month ago. I took the truck on a 300 mile trip today and over all the egt's at 70mph are about 80 to 100 deg. cooler. Some of the hill's I used to get over 800 deg now some hill only about 650. It was a little cooler out then the last time I took trip by about 20deg's. Overall I think It was worth the install. The new I/C covers the entire core support opening. If you could find the I/C cheap I think that it's a better and easier fit than the new dodge I/C.

 

[matches]

Was the intake horn a direct bolt on?

 

[JRussell3176]

So if 1* of ambient temp equals about 3* of EGT temp, then your EGT's should have been about 60* lower due to the outside temps. That would give you an actual reduction of 20* - 40* EGT-wise, which is pretty damn good for just cruising at 70mph. Have you checked max EGT reduction yet?



Anyone else who does this mod, you MUST buy an air intake temp gauge FIRST so we can get real world numbers on this sweet mod!

 

[one_ton]

ps ic

i have a 2004 power stroke i/c in abox waiting to be put in. i am waiting to up grade my turbo first. then i have to gathe up some tubing. hopefully in the next two months.



bob

 

[JLEONARD]

That would give you an actual reduction of 20* - 40* EGT-wise, which is pretty damn good

I have read that the rule of thumb is for every 10 degree rise in intake air temp you get a 1% power loss (or efficiency loss).

You can do the math.

Jay

 

[JRussell3176]

That would give you an actual reduction of 20* - 40* EGT-wise, which is pretty damn good

I have read that the rule of thumb is for every 10 degree rise in intake air temp you get a 1% power loss (or efficiency loss).

You can do the math.

Jay

Not without knowing the intake temp changes, I can't. Is there some sort of general rule-of-thumb for what intake temp changes equal in EGT?



I plan on doing this swap sometime in the near future and might get an air intake temp gauge now so I can monitor the water/meth system too.

 

[DanaLittle]

matches the intake horn is a direct bolt on.

 

[matches]

Thanks, I'll start shopping today!!

 

[bgilbert]

Next is the injectors I bought from New ERA Diesel edm's . They had a group buy on them a while back.

I must of missed that group buy. Did they rate them or give any particulars about them?

 

[DanaLittle]

Bgilbert-- Looks like www.neweradiesel.com still has their injectors on sell. They don't list them for the first gens but if you tell them what you got the will give you the 12v prices or you can just custom order a set. Lot's of guy's at cumminsforum.com like the 435's they sell for the 12v.