Adding An Intercooler

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Adding An Intercooler

Postby hmknight » Wed Jan 10, 2007 6:32 am

Hey Guys,

I'm looking to add an intercooler to my '89. Not planning to go quite as large as Greg did with the 3rd gen cooler, but I have no qualms about hacking up my radiator support and grille to make one fit.

So I come to you wondering what my options are as far as intercoolers go. Do intercoolers off 2nd gen trucks fit well? Also, what kind of clearance issues should I expect in the engine bay? A/C and related piping is already gone.

Has anyone else done this before? Is adding one to a non I/C motor worthwhile? (I plan on doing a compressor upgrade later on, and turning up the pump some perhaps.)

Thanks
Harlan
1989 D250, 727/3.08, 3in straight pipe, homemade flatbed, 310k.
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Postby sdstriper » Wed Jan 10, 2007 8:02 am

The 1999-2003 Ford PS is supposed to be a good adaptation for the 1st Gen. After 2001 they went to plastic tank fittings, mid 2002 actually. The guys are using stock 3rd gen tubes cut down to fit. Hump hose connectors etc are readily available online.
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Postby g1625s » Wed Jan 10, 2007 5:17 pm

Harlan,
An intercooler is definitely a worthwhile addition. As has been noted, a 3rd gen Dodge IC just plain don't fit :lol: but the late model powerstroke units, as well as the 2nd gen Dodge units seem to nest in the core support just fine, with some hacking, of course.

As for fitment, I had to hack away pretty good at my battery tray, but I think with an intercooler that isn't so tall, you'll be able to locate the inlet a bit lower to avoid clearance issues.

Also, look for an intake horn that points forward like the one I'm using, aso opposed the the one that points sideways like the stock ICed first gen. Our booster/master cylinder is different and any associated piping WILL hit with a sideways facing intake horn. Good luck! I'll post up soem pics of mine here in a sec...
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Postby g1625s » Wed Jan 10, 2007 5:25 pm

Ok, I started here:

Image

Added huge IC:

Image

All mocked up and looking...well, stock-ish...

Image

Fitment pics..., notice the booster:

Image

Image

...having a maxed pump and a pyro that's worthless over 1000 even when towing---priceless:)
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Postby TWorline » Wed Jan 10, 2007 5:35 pm

Harlan:
Hey welcome aboard! There is a `92 grille on eBay, it was on there a couple of weeks ago & didn't get a bid because it is local pickup only, the opening bid is only $25.00. This grille is made for an intercooler. Check it out here http://cgi.ebay.com/ebaymotors/92-Dodge-Ram-Diesel-250-350-Grille-87-88-89-90-92-81-93_W0QQcmdZViewItemQQcategoryZ33645QQihZ003QQitemZ130067681562QQrdZ1

Oh yeah I forgot to mention that it is in MA.!!! 8)
Last edited by TWorline on Wed Jan 10, 2007 5:54 pm, edited 1 time in total.
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Postby g1625s » Wed Jan 10, 2007 5:50 pm

In addition to that grille, you also need the blinker assemblies and the filler panel between the bumper and grille as they are different from the old style. I'm in a tight spot because I don't think the filler panel will clear my IC, but it would likely clear a PS IC. Those blinkers are pricey, too. I'm watching the local boneyard and stockpiling pieces one at a time.
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Postby hmknight » Wed Jan 10, 2007 6:56 pm

Thanks for the welcome, and the replies.

So I need a front-facing intake horn...with a 90* elbow right after. That looks simple enough to do. Anybody know if any medium duty trucks / school busses with a 5.9 would have that sort of horn? I'm thinking about grabbing most of the plumbing from a truck boneyard down the street. Greg, where'd you get your plumbing from? (Also, I love the 3rd gen I/C in that 89. )

As for the grille, I seem to remember seeing a real nice silver D-350 crew cab on DTR with an '85 grille, and an intercooler stuffed behind it. Just looked at that ebay ad, that grille is in the next town over, what are the chances?

Also thinking about getting a 16cm exhaust housing. Does that make a big difference with the turbo lag?

Just trying to find ways to blow the money I'll be making with my new job :twisted:

Keep the responses coming, I really appreciate it!
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Postby DLittle » Wed Jan 10, 2007 8:24 pm

I did the powerstoke I/C in my 93 W250 and it was a real easy swap. I also used the intake horn and I/C tubes off of a 2002 dodge and everything looks stock. I don't think that you will see a big improvement with the 16cm housing verses your 18. Just turn the fuel up more.
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Postby sdstriper » Thu Jan 11, 2007 2:44 am

Harlan, FWIW that is the more desirable OEM grille surround. It has the black Dodge embossed on it and I don't know if they are even available that way now. You can get them w/out I know. Pick it up if you can, you could always sell it and ship it, unlike this seller. It is worth a bunch more than what he starting at there.
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Postby g1625s » Thu Jan 11, 2007 5:26 am

hmknight wrote:Thanks for the welcome, and the replies.

So I need a front-facing intake horn...with a 90* elbow right after. That looks simple enough to do.

Well, I sorta jumped the gun a little---our trucks simply have the intake plate reversed when compared to newer trucks--the hole is not on center. However, flipping the plate around may require removal of the injection lines...


Anybody know if any medium duty trucks / school busses with a 5.9 would have that sort of horn?

The one you see in my pics is from an FL60 and is of the true 3'' variety:)

I'm thinking about grabbing most of the plumbing from a truck boneyard down the street. Greg, where'd you get your plumbing from? (Also, I love the 3rd gen I/C in that 89. )

I got my IC on e-bay and it included all of the associated plumbing, save for the intake horn. I was able to use almost every inch of the factory 3rd gen stuff, saving some $$$

As for the grille, I seem to remember seeing a real nice silver D-350 crew cab on DTR with an '85 grille, and an intercooler stuffed behind it.

Maybe a stock 1st gen IC could be shoved back there, but the 2nd gen and PS units are much thicker, so I doubt they would fit. Another thing to consider is hood latch issues. Everything structural has to be removed in order to fit anything in there--that's why the intercooled core support is so desireable.



Just looked at that ebay ad, that grille is in the next town over, what are the chances?

Also thinking about getting a 16cm exhaust housing. Does that make a big difference with the turbo lag?

don't waste your $$$. the 18.5 is fine, especially with an auto. Some AFC tuning will have you spooling nicely

Just trying to find ways to blow the money I'll be making with my new job :twisted:

Keep the responses coming, I really appreciate it!



wordsoutsidethequote
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Postby hmknight » Thu Jan 11, 2007 8:57 am

g1625s wrote:Well, I sorta jumped the gun a little---our trucks simply have the intake plate reversed when compared to newer trucks--the hole is not on center. However, flipping the plate around may require removal of the injection lines...



I like this idea, of just spinning the cover plate around. I'll investigate this tonight.


g1625s wrote: The one you see in my pics is from an FL60 and is of the true 3'' variety:)


Awesome, an FL60 should be easy to locate in the yard.

sdstriper wrote: Harlan, FWIW that is the more desirable OEM grille surround. It has the black Dodge embossed on it and I don't know if they are even available that way now. You can get them w/out I know. Pick it up if you can, you could always sell it and ship it, unlike this seller. It is worth a bunch more than what he starting at there.


I'm pursuing the seller about selling locally.

g1625s wrote: Maybe a stock 1st gen IC could be shoved back there, but the 2nd gen and PS units are much thicker, so I doubt they would fit. Another thing to consider is hood latch issues. Everything structural has to be removed in order to fit anything in there--that's why the intercooled core support is so desireable.


Another issue I've just realized my transmission cooler will be in the way. My stock cooler burst over the summer so I ended up with a auxilary oil cooler off an International truck. Isn't tucked up top like the stock one was. 91.5+ grille is sounding more appealing by the minute.

Thanks again guys
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Postby RumbleFish » Sat Jan 13, 2007 6:54 pm

Don't forget that the headlights are in a different location on the 91+ trucks than the 90 and older. Look for a different core support or plan on modding yours.
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Postby MMiller » Mon Jan 15, 2007 12:23 pm

Please tell me you washed the radiator before installing the aftercooler? :shock:

Michael
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Postby g1625s » Mon Jan 15, 2007 5:03 pm

yeah, and that rad. had only been in for about 6 months. I never really noticed how dirty it was till I looked at the pics that night on the computer.
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Postby hmknight » Mon Jan 15, 2007 7:57 pm

I picked up that grille Thursday night. The guy had an absolutely MINT '92 W-250. Never seen such a sharp looking truck. Had a sweet 68 Dodge dump truck he was looking to stick a 5.9 in too. And he's lived 2 miles away from me all this time.

Drove the truck 750 miles round trip up to central Maine. Loved every minute of it going up 95. Only spent $50 on fuel too :D

Anyway, I'm still chasing leads for a 7.3 intercooler and some piping. Also wondering about guages. Thinking about getting a boost and pyro - what's the scoop on guages guys? Brands? Suggestions?

Thanks again!
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