Intercooler options

[Mattster]

I got a 91 D250 N/I and am exploring my options for intercooling it. I read the write up on putting a 2nd gen intercooler in and was thinking of using a Powerjoke one and removing the A/C so I had more room since I don't use it anyway. From talking to Tim he would have to make a custom tube to go from the intake manifold to the intercooler to clear the master cylinder. I have always considered Air/Water intercooling and have found a site with everything needed including a separate radiator for the intercooler, I was thinking of possibly going this route, have a 2.5 or 3inch tube go over the engine like stock N/I engines and mount the intercooler on the passenger side somehow and mount the smaller radiator where the a/c condenser was.

Just trying to cover all my options, I have even considered a top mount intercooler like Subarus have and I have even seen a 6.5 turbo diesel with one like that with good results but the 6.5 runs lower boost so I'm not sure if it would work as well in my application but it would look pretty cool.

Thoughts on this?

[rbrettctd]

I have a PS intercooler with a/c still functional. Lots of work but its in.
Keep in mind, you can flip the intake plate so the inlet clears the master cylinder...thats what I did, and just had to cut the throttle plate and create a new mounting bracket for it. Ill get some pics of my setup on here after the first of the week.

I originally was going to do the air/water but changed my mind. Still might add the A/W cooler in the middle of my hotside line.

[flashgordon]

Well with the 2nt gen intercooler and the waste gated turbo....mine runs a hole lot better and seam to have dropped my EGTS by 350*.............it still hasn't gotten above 50* around here so it may not be that good........... but I'm pretty sure i will be able to remove the collar on my fuel screw now!!!!!

egt are running a 900* and last year before the 2nt gen intercooler project i would have had to lift, when it hit 1250*........
it hasn't got warm enough to compare apples to apples.........But it sure looks promising!!!!!!
Can't even lug it and make it go much over 900*

As far as removing you ac......It might help to keep you stock grill

The power stroke cooler take a lot more work, as the cooler tubs run right in the way of the main support of a early 91 and older.
the 2nt gen is wider and eliminates this problem.
The factory intercooled trucks have the support or reinforcement out further, allowing the PS cooler to fit in between.

Just some more food for thought

Flash

[Mattster]

So its probably best to get a 2nd gen intercooler like the 24v ones?

[flashgordon]

So its probably best to get a 2nd gen intercooler like the 24v ones?

My intercooler is a 12V one.(94-98 The only difference between the 12v and the 24V(99-02) is they add one more cooler tube row to it....Making it 1 inch taller and requires that the brace under the hood latch be completely removed! and the secondary hood latch needs to be majorly modified to clear the cooler!

Other then that, it install the exact same way.

I wish you could just install the 91 and up grill and be done with it.......but the head light bucket need to be raise up to accommodate the newer grill.

whether you go with PS or 2nt gen cooler, grill space is going to be a problem.
I don't know if i put the proses it took to raise the head light up to accommodate the newer grill on here but it is at D.T.R in the "sticky.

rbrettctd, I would real like to see then pic's my self............Was you able to keep you stock grill!

Edit just realised yours is a 91 early just like Mine

Flash

[Philip]

I'll be testing a 1st gen IC that has been moded with 3" in and out tubes in a week or two. I'll post when I get it installed.

I have to replace a broken steering box mount before the IC.

[big specht]

We are looking for a good repacement for the first gen innercoolers too. If any body has some pics with one installed with in a first gen with a/c and auto tranny it would be helpfull . We have a bigger tranny cooler in it already and had to cut the grill to get it to fit with the a/c condensor. it has the 91 style grill in it

[CumminsPride]

What is ATC's???

[dazedandconfused]

Did Banks quit making intercoolers for them?

[rbrettctd]

Ya the only way to find them are old stock and used. 7.3PS and 2nd gen intercoolers are more efficient anyhow.

[big specht]

What is ATC's???

3WHEELER

[CumminsPride]

T Y!

[shadrach]

In my buddies 93 W350 we took a stock 1st gen cooler and changed the ends to 3" and added a 1" thicker rad. It runs cooler now,especially since he has a monster winch mounted on is front deck. BTW he has 96 engine in there so we used the stock 2nd gen piping. Shadrach

[shadrach]

In my buddies 93 W350 we took a stock 1st gen cooler and changed the ends to 3" and added a 1" thicker rad. It runs cooler now,especially since he has a monster winch mounted on is front deck. BTW he has 96 engine in there so we used the stock 2nd gen piping. Shadrach

[GO OVRIT]

I hacked off the tubes on a bank$ cooler and used 3" tubes. That combined with the 3" cooler tubez from Tim Worline dropped the egts pretty good. If I had to go out and spend money though, I'd look for a 2nd gen cooler and run Tims tubes.