INTERCOOLER UPGRADE

[blacksheep]

i have a 91 dodge with the intercooler. how good is the factory, and at what point does one need to upgrade it. what is available for these?

[comotionman]

The stock ic put in 1stgens is better than nothing, but its undersized. The inlet/outlet tubes as well as the air horn are also undersized. Recognizing this, when I went to put an intercooler into my non ic 90 I didn't bother with the 1stgen stuff. I went with a psic, which is the abrev for powerstroke ic. Another and I feel better choice is the 2ndgen unit. You really can't go wrong with either. Along with 3" inlet/out charge tubes and an air horn with 3" inlet and you'll be set. I want to say around the 400hp level it becomes a real restriction but I am not sure, but the fact that the larger setup will provide cooler temps in all situations tells me the stock ic is an inferior setup.

[RCCUMMINS89]

Mine was efficient to about 400rwhp. After that, it just made heat.

[blacksheep]

i will be putting a p-pumped 12v that should be 6-800 hp.

[blacksheep]

The stock ic put in 1stgens is better than nothing, but its undersized. The inlet/outlet tubes as well as the air horn are also undersized. Recognizing this, when I went to put an intercooler into my non ic 90 I didn't bother with the 1stgen stuff. I went with a psic, which is the abrev for powerstroke ic. Another and I feel better choice is the 2ndgen unit. You really can't go wrong with either. Along with 3" inlet/out charge tubes and an air horn with 3" inlet and you'll be set. I want to say around the 400hp level it becomes a real restriction but I am not sure, but the fact that the larger setup will provide cooler temps in all situations tells me the stock ic is an inferior setup.

which one fits better a psci or going with a 2nd gen one? i have a 2nd gen out of a 98 dodge that i can put in it.

[BC847]

i will be putting a p-pumped 12v that should be 6-800 hp.

I wonder if that proposed is gonna support your ultimate goals. No need in spending money twice.

Getting the air through the complete charge-air circuit (intake, engine, exhaust) can be just as difficult/expensive as the fueling circuit (lift-pump, Injection-pump, injectors, etc).

[RCCUMMINS89]

I actually gained boost when I went to a 2nd gen set up. That goes to show just how restrictive it was.... I literally couldn't even get the air through the stock I/c.

[BC847]

Random thoughts:

In a perfect world, the circuit that carries the charge-air from the turbo(s) to the intake-log, is gonna present with as little pressure-drop as possible.
I've got a DATA logger thingy and the last time I messed with it, @ WOT, with 56.4psig coming out of the secondary, I was getting 54.5psig at the intake-log. Right at a 2psig pressure drop across the IC and associated plumbing.

To complicate the above as far as that pressure drop, when you cool the charge-air, it shrinks in volume. With that, the "boost" number on the IC's outlet is gonna be lower compared to the inlet.

Don't get carried away with the pipe sizes as once you get past the point of worthwhile reduced pressure drop across the pipes, you end-up increasing the overall volume of the circuit, which equates to turbo-lag type issues. You're having to fill that tank with compressed air so to speak, it takes a minute or two for a big tank.

So say the voices.

[carsonc1974]

have you considered a water to air I/C? Its not even comparable but i had great success on a turbo'd VW