illflem,
Years ago I did the same modifications to my airbox (4" hole in firewall and oval in bottom of stock airbox)in order to keep EGTs down. This was the first step. I then acquired a exhaust blanket to reduce the heat near the intake. Next I insulated the airbox with some aluminum backed fiberglass. All of these seemed to help the EGTs. Then I bought an RE0880 with the foam sock and started all over. My final mod was to use a 8" airconditioning T as a filter housing with the leg of the T pointing to the stock fender air hole and the top portion acting as the psychotty filter housing. All this is wrapped with insulation and an insulated cowl connects the leg of the T to the stock fender opening. All hot engine air is insulated from the filter and only ram cold air from the firewall and the fender enter the filter housing. This works extremely well for me and I run a #5 TST plate with stock turbo on an original 215hp engine - a supposed no no due to high egts. I advanced my timing to 16 which helped the egts as well. As long as I don't run my rpms too high (I stay in the 1800 to 2300 range) I can run hard up the hills with 20,000lbs gross and keep cool. My next step was to install a mist system in front of the intercooler to use when things got too hot but I have found that I don't really need it. An example of my exhaust temp was this evening on my way home I was pulling 20,000lb gross up a steep hill at 60mph, 2000rpm, outside temp 82 degrees, boost 32lbs, and exhaust temp was 750 post turbo. I have run the same hill at 40+ lbs of boost and had 950 to 1000 degrees post turbo but my engine rpms were climbing past 2300 and I was definitely over the speed limit of 55mph.
I haven't made any more mods in a couple of years now but keep toying with the idea of the mist system just to see what difference it might make. I used one in a race jeep with a 400hp 327 engine and it helped significantly. I had a custom radiator built but there was only so much room in that little jeep and the mist system was the only thing that really worked.
Well, I've rambled enough. Maybe this will give someone an idea to play with. Let me know if you have any questions about any of the above.
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96 2500 4X4 5sp 4:10 215hp SLT Horton fan,#5TST plate,AFC spring kit, advanced timing,4"exhaust,GearVendors,BFG 285/75/16 on Mickey Thompson Challenger wheels, RE0880 in insulated housing, Detroit Locker,50#Boost and Pyro guages, Aluminim flatbed, gooseneck and bp hitches,Helwig air bags with compressor, Helwig sway bar, Rancho 2" front lift w/9000 shocks all around, Preluber w/aircraft hoses,Hytec rear cover,PacBrake,McCleod dual disc clutch,numerous other accessories. Pull 11,000lb aluminum gooseneck horse trlr. and 14,500lb equipment trlr.