Stupid Intercooler!

[PToombs]

I didn't think it was running right,my boost #'s were never as high as every body elses. When I put my 16cm housing on it cut the smoke quite a bit,and boost at 70 mph went from 1 or 2 to about 3 or 4. Well I hooked up the trailer and put the small tractor on and went to get a set of plows, taking the same route I take to work. At 60 mph, about 10 psi and egt at 1250* WOW! Houston we got a problem! At 70 mph 12. 5 psi and the same egt, but it didn't go any higher, thank goodness it rained, egt came down 100*. Tonite I pressure tested the intercooler,set the regulator at 20psi,hooked it up,no pressure on guage. Removed the POS and it looks like it got termites. I love living in the "salt city". Where can I get a better or bigger IC for a reasonable price? Any help would be appreciated. Thanks guys.

 

[Slim]

Hey PTooms, sorry to here about your cooler. I got an intercooler off the e-bay for a song. I only paid $300 Canadian and I am very happy with it. Mine came from XSpower you could look them up on e-bay or the net. There was a little bit of mods to do but a huge difference over the stock intercooler.

 

[bgilbert]

Stay away from used intercoolers, they leak. Last I heard PDR was still selling a new replacement for our 1st gen IC. Banks sells one too. BTW I still get 38psi of boost but my cooler won't hold any pressure when testing LOL... . just blows all the air out the front of the IC. . wonder how hard I'm actually pushing my pdr35-16?

 

[Greenleaf]

Now Bill..............

You know that IC of yours was just fine when you bought it... ... ... .....



Untill that pesty little neighborhood kid used your grille as a backstop for his BB gun targets.



:-laf :-laf :-laf



GL

 

[BJMarshall]

BTW I still get 38psi of boost but my cooler won't hold any pressure when testing LOL... . just blows all the air out the front of the IC. . wonder how hard I'm actually pushing my pdr35-16?

Are you going to be looking at PDR to warranty that turbo when it goes south from an overspeed condition?

 

[bgilbert]

Are you going to be looking at PDR to warranty that turbo when it goes south from an overspeed condition?

Didn't know they warranty performance products. But no, bought it from a TDR member new in box. Got a 40-16 sitting on the bench waiting if it does say goodbye. .

 

[formula]

Didn't know they warranty performance products. But no, bought it from a TDR member new in box. Got a 40-16 sitting on the bench waiting if it does say goodbye. .

FWIW, if it does say "goodbye"..... You'll likely have to be replacing / fixing more than just the turbo.



Sean

 

[Greenleaf]

I wouldn't worry 'bout it Bill. Somone once told you that because you blew a boost hose your turbo would self destruct. I'm still waiting for yours to become ingested so I have a heads up.



Keep us (me) posted.



GL

 

[PToombs]

I called around some today for an I. C. . Talked to a guy at Banks,he said their IC flows about 60% more than stock. I said ok, how much?He says "the kit (cooler,brackets,and hardware)is $1036" I peed myself on the freakin' spot. Got his name and told him I'd let him know. I was hoping to spend around $500,maybe 6. Called PDR,they might have one, gonna get back to me. I may have to go back to plan A,install pipe direct from hose A to hose B so I can drive it Thank goodness we have 3 vehicles on the road.

 

[Idually]

Hello Guys. I'm not trying to hijack this thread but I have a similar situation. I pulled the IC out of my 93 last night and found some rubber caps, and valve stem so I could put some air into the IC. I'm assuming that the IC SHOULD be holding some air pressure. I set the regulator on the compressor low (ABout 15psi at the compressor) in started to fill the IC with a bit of air. The air leaked out immediately. My caps are secure. It seems to pressurize but it won't hold any air. Should it be capable of holding air? I was getting ready to finally get EGT and Boost guages to install over the 4th of July weekend, but now I might be buying an IC?



Thanks for any input.

 

[dodgenstein]

The intercooler ideally should hold air as well as an air tank. Spray the cooler down with some soapy water, then air test it again. Any leaks will be evident. Regardless of what you read on here, all used IC's don't leak. I bought one on E-bay and checked it, NO LEAKS. I also have one from my project truck that was damaged in a previous wreck, and NO LEAKS. They were both pressurized and held air for about 3 min. till I let it out.

 

[Idually]

Thanks. In that case it's leaking bad. I have spent the better part of the day chasing the holes, cleaning them up, and patching them with JB weld Kwik. Only temporary... I will be call Piers on Monday and ordering a new one. I did however come up with a cool way to test them, so not all is lost.



Thanks.



Andrew

 

[TKingsbury]

Cummins has a procedure and a spec to intercooler leakage. I don't recall exactly what it is without looking it up, but some leakage is acceptable. I would think if it will hold pressure for a minute or more it is very good from my experience.

Travis. .

 

[frijoli]

Has anybody tried to have their IC recored at the rad shop yet?? Not sure if it can be done due to the tanks/end caps are alum. But if Banks wants a grand for theirs I sure think it is worth a try. I do not have a junk first gen IC to try it with . If anyone does I would be glad to give t a try... ...

Getting back to this, has anyone attempted it? Surely you can order cores?

Clay

 

[BushWakr - RIP]

At the shop we use a very simple test proceedure and it works well... . I've posted on this one before but we do just like Idually mentioned. In the case of testing while the IC is on the truck you'll have some "leakdown" because the valves are not all closed at the same time. We usually pressurize to about 20psi. . not because of limitations but rather to keep the boot/valve cap we use from blowing off onto the back of the alternator...

Often times an IC can have a fair number of pin holes in them and still remain quite servicable... I don't mean a couple hundred BB holes ... but they will work ok till you can get hooked up with a new unit.



On another topic... if the hx35 is one of ours all I can tell you is mine has survived (with no apparent ill effects) runs up to47psi with EGT's pegging as high as 1800*F.

I'm not saying they will ALL survive this kind of abuse but you gotta admit, that is durable.

The hx40's are a little less durable to the fact that they use the same shaft as the '35.



pb... .

 

[JimmyDiesel]

hey,



I am in the same boat, just pressure tested my ic and found swiss cheese. City Diesel has a 'cool twist' ic thats costs $795 (exchange). Thats better than the banks price, and both claim similar gains over stock.



Does anyone have any experiance with the cool twist ic? I have to order one soon.



thanx,

jimmy

 

[CLiberty]

ugghhh, I`m afraid to check mine, it sure looks ugly, esp on the bottom roe of tubes.

 

[PToombs]

Piers just got 4 in last week, but 2 of them were sold already. One of them was mine should be here any day. Little over $600. It figures, i'm going on vacation, leaving sunday morning, so it will show on monday :{ I thought banks was way outta line with their price. My by-pass tube works good, EGT's are down from before, so the IC was leaking bad. Mark at PDR says they should drop another 150 to 200* with the new IC.

 

[JimmyDiesel]

I talked to a salesman named Manuel at Banks and they said that they are not making their ic for 1st gen's anymore. They had one left and they would give it to me for $976 including shipping to New York. I still think the price is too high. I'm probably going to go with the City Diesel ic - unless anyone knows of a better option..... ?



-jimmy