Upgrading from Non-intercooled to intercooled

[benhall]

Are there any companies that make upgrade kits anymore for the 1st gen trucks? I know banks used to have one, but have discontinued it.



Ben

 

[therabbittree]

just get second gen intercooler and make some intercooler pipes for it. a ford powerstroke intercooler is a good swap size. I did a second gen intercooler into a '89 and still got the grille to fit. Its a thinner grille now but it looks like a regular '89 grille.

or get the parts from a intercooled 1st gen.

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later

Deo

 

[benhall]

Thanks for the info Deo. Did you have to rotate your turbo at the same time?



Ben

 

[dpuckett]

May as well upgrade the turbo while you're at it. This is an expensive process, I know- upgrade to an intercooler, get a new(er) turbo,l intake system from ASA, etc. But, with your compressor outlet, you will have a problem with getting an elbow to line up. Or you may not- depends on your skills. You will also need an intake horn from an intercooled truck. Not hard to come by if you can wait a while for one to pop up on ebay.



If you get a non-Dodge intercooler, make sure it has metal ends- not sure how plastic holds up to 30-40psi on a regular basis.



WHy are you wanting to intercool?



Daniel

 

[benhall]

When I do the conversion on my crew cab, I would like to have it intercooled. No particular reason, just like knowing that my motor is getting the coolest air possible and I like the cleaner look under the hood.



Ben

 

[CSchafer]

PM member GLHS, I think he has a couple intercoolers for a first gen for sale. If you are going to keep the baby H1C you will need a pipe that turns 90 deg. and conects with a hose. If you want to up grade turbo's to a newer style you will need the 90deg turn that hooks to the turbo with a v band clamp and has an o-ring seal. I got this from the dealer and everything was about 100 bucks. But i'm sure it would be cheaper if you can find it in a junk yard. If you go that route all you need is a straight piece of pipe to go between the intercooler and turbo. If you have access to a welder both side pipes can be made from exhaust pipe fairly easy. If not the easyiest route would probobly be to find an intercooled truck and get all the parts you need.

 

[Greenleaf]

I don't see that it would be worth the expense/trouble unless you intend to pull heavy loads most of the time on long trips. A simple upgrade of the turbo/exhaust manifold and intake/exhaust system will serve to provide dense air flow.

 

[JLEONARD]

If you are going to put in an intercooler don't even think about keeping the baby H1C. Not worth it.

Upgrade to at least a standard H1C with a stage something kit.

 

[Jgolden]

JLeonard, what is the difference between "baby"H1C and standard? I might have read it here someplace but info keeps "age-ing" out on me. Thanks.

 

[dpuckett]

The "baby" H1C is what you have on your nonIC truck. It has a 3" air filter hose inlet, 50mm impellar, and a straight outlet to put a hose on. The later H1Cs had a 4" inlet, 54mm impellar, and a flanged outlet to put an elbow on.



-DP

 

[benhall]

I plan on putting the same turbo that my 02 HO has. I believe its the HX35.



Ben

 

[JLEONARD]

An HX35 would be a good choice.

 

[Moab4x4]

?? regarding H1C impeller size. HTT was telling me that on the intercooled trucks the impeller was 56mm on 3/4 ton trucks and 54mm on 1 ton trucks.

Sounds odd doesn't it?



Can anyone verify or debunk this one? Curiosity only...

 

[Greenleaf]

I have an H1C from a 93 D350 installed onto my 90 model truck. I'll look at my notes and post it up here after lunch... ... ... ... ...





Later that same day... ... ...





I found that the turbo removed from a D350 is 54mm impeller. I never measured the OEM unit I removed from my '92 D250. Sorry.



You don't want to mess 'round with a small unit. You need 60mm or larger to provid the air. Remember cool/dense air flow NOT boost. You want to customize the turbo to operate just inside of the map range @ the rpm/load/speed you will run in MOST of the time. That way the turbo is providing the cool dense air and not pushing it's outer limit which will then begin to supply HOT air.



Only you can supply the answer. Run it by Paul @ HTT and report back what they recommend.

 

[JLEONARD]

Moab,

I read this on their web site and talked with them about it a couple of years ago... that's when they told me the "baby" is 50 mm.

Doesn't sound strange to me... . that means the H1C can be a 50mm, 54mm, 56mm or maybe even more variations.

The housings have different inlet and outlet sizes, different exhaust housing sizes.

In summary..... all H1Cs were not created equal. Hence the word "frankenturbo" in my signature... . part baby, part H1, part WH1, part aftermarket. Perhaps "Heinz57turbo" would be a better term.

 

[Greenleaf]

Her Heinz. . Jah!