1st gen intercooler into N/Ic 1st gen
 

I finaly got all my parts for an intercooler install and decided to to a little write up on it.

With this install you WILL NOT be able to retain you're A/C condensor also with this install I flipped the I/C upsidedown

Tools you'll need

Socket set and rachet with a few extensions,a couple screw drivers,drill with assorted bits, sawzall wit a sharp blade, a sharpie, and a tape measure

Parts you will need

1st gen intercooler,1st gen piping, 8 2 1/2" t-bolt clamps or constant torq clamps, 1 2 1/2" v-band clamp, 1 90* v-band elbow, and 4 2 1/2" hump hose boots


First start by removng the Headlight bezels, grille insert, outer grill shell and lower filler panel

http://i547.photobucket.com/albums/h...install002.jpg


Next remove the radiator and A/C condensor if equipped

http://i547.photobucket.com/albums/h...install003.jpg

Now measure 7" down from the bottom side of top of the core support and make a mark, now measure 5 1/4" down from that mark and make another mark, now measure 3 1/2" over from the radiator opening in the core support and make a mark, and repeat on the other side of the support

http://i547.photobucket.com/albums/h...install007.jpg

Once you have your core support cuts laid out you can go ahead and fire up the sawzall and start hacking

http://i547.photobucket.com/albums/h...install008.jpg

Some additional trimming may be required


Now that you have your holes cut in you're core support you can go ahead and and start fitting you intercooler


http://i547.photobucket.com/albums/h...install010.jpg


Now establish where you need to drill your mounting holes (I just held the cooler where it looked centered and marked it with a sharpie) once this is done you can go ahead and drill the holes

http://i547.photobucket.com/albums/h...install012.jpg

You can now measure the space between the core support and the mounting tabs of the cooler, make a note of this measurment and measure the other side, make a note, now you can go cut you're spacers out of some pipe or whatever you got layin around(my measurements were 1 13/16 on the pass side and 1 1/2 on the drivers side

Once you get you're spacers cut you can bolt the cooler in place( remember to put some thin strips of rubber between the cooler and the core support)

I used some 3/8 bolts 3 1/2" long and used fender washers.

http://i547.photobucket.com/albums/h...install013.jpg
http://i547.photobucket.com/albums/h...install014.jpg

Now you can hook up all you're plumbing

http://i547.photobucket.com/albums/h...install006.jpg
http://i547.photobucket.com/albums/h...install004.jpg

Next you will have to trim the radiator mount to clear the inlet and outlet of the cooler

After this is done put the radiator back in the truck


I will post more tomorow after I trim the lower filler panel and get the grille installed in the truck

Looks nice. Is the crossover 45 gonna get passed on again?

Thanks and yeah after my 2nd gen horn gets here, as you can see I'm still using half of it

Looks good Andrew. Did you get the getrag back together and on the road? I had a 2nd gen intercooler you could have bought from me!

I haven't got the rag back together yet,waitin on parts

The reason I used the first gen I/C was cause one I already had it and two I'm tryin not to hack the heck out of the grill insert

I would add that if you haven't done put the tab in for the killer dowel pin this would be a good time to do it. That is my plan when I do this swap as I have most the parts for it minus an intercooler.

With that intercooler you shouldnt need to trim any thing,just modify the hood latch brace.I had to add a spacer at the bottom of that brace to.

Good write up, make sure you tune us in on EGT drops/boost numbers after the install.

I got the grille and every thing put back together today

This is what I had to do

I trimmed the lower filler panel to clear the cooler and to get more air through it

http://i547.photobucket.com/albums/h...install021.jpg
http://i547.photobucket.com/albums/h...install020.jpg

I then installed the outer grille shell

http://i547.photobucket.com/albums/h...install019.jpg


Next you'll have to trim the back of the grille insert(I ended up cutting a lot more than I wanted to but I guess when I do a PS I/C I'll have enough room)
http://i547.photobucket.com/albums/h...install024.jpg
http://i547.photobucket.com/albums/h...install026.jpg


I'll probably end up making some stainless steel inserts for the grill so it'll look a little better

http://i547.photobucket.com/albums/h...install025.jpg

Driving Impresions

I noticed EGT's dropped 50* at idle, it dropped 100* at cruiseing speed and dropped 200* at WOT

I also noticed a 10 psi drop in boost but later discovered a small boost leak in one of the cheesy factory boots, I will report new results after Iget some new silicone boots on the old truck

On the test drive I saw a max boost pressure of 36PSI and a max EGT of 1250 degrees, and the climb there was a lot slower

All in all I'm very pleased with my install and would recomend it to anyone with a N/IC truck that can live without A/C

"go ahead and fire up the sawzall and start hacking"


My thoughts exactly. Right on son! Git R Done

what about those of us that cant live whithout A/C.? does a 2nd gen fit for that?

Well with as much as I trimmed off the grille I could probly fit the condensor back in, which I might do, or you could mount the condensor somewhere else.

I have also heard the factory intercooled trucks had a thinner condensor you could use also.

Is there any truth to this?

How much room do you have between the core support and IC end tanks? You couldn't stuff it any closer? I'm gonna get some pics of mine within the next few weeks.

There is no room between the tanks and the core support

Well on the intercooled model, I fit my ac condesor right in between the intercooler and raditor.. It was like it was supposed to be there, thats how nice it fit.. Here is a few pics

http://i132.photobucket.com/albums/q...e/IMG_0595.jpg
http://i132.photobucket.com/albums/q...e/IMG_0597.jpg
http://i132.photobucket.com/albums/q...e/IMG_0642.jpg

Does that 2nd gen cooler got aluminum tanks

Why did you flip your cooler

Ya.. the 2nd gen is aluminum.. I flipped the cooler because the angles were better for the plumbing to the intake horn and the hot pipe coming off the turbo... And I like to be different... It worked awesome... I only wish the the tanks were more like the powerstroke intercooler... But i got it for free, so it was all good..

http://i132.photobucket.com/albums/q...e/IMG_0669.jpg
http://i132.photobucket.com/albums/q...e/IMG_0667.jpg
http://i132.photobucket.com/albums/q...e/IMG_0668.jpg

all that im saying is that dnr did it better but stilll good job

What kinda temp drops did you see with the 2nd gen cooler over the 1st gen unit

Clean install, I like it

I got a spare core support and know where ican get a 2nd gen I/C so I might rearrange some stuff

I agree......

You kept the factory non-ic radiator in there correct?

Well, here's the skinny... I bought the truck as a basket case and never really drove it before I ripped into it... So I don't know a before and after... But I do know that it has to flow real good, I don't have any crazy kinks or bends.... the most i seen on the egt is 1050-1100 wot with the converter locked up with 1k in the box and about 30psi of boost... Nothing crazy, but i do feel the potential for more fuel without crazy egt's...

Yeah I wasn't sure if it was a runner when you got it


Mattster yes this is a N/IC rad

Update
 

Got my 12v air horn today

http://i547.photobucket.com/albums/h...install030.jpg
http://i547.photobucket.com/albums/h...install028.jpg
http://i547.photobucket.com/albums/h...install027.jpg
http://i547.photobucket.com/albums/h...install029.jpg

Within the week we will have some new silicone boots on everything

Well I changed it up again today

I got a 24v horn, and I fabbed up a stainless pipe

http://i547.photobucket.com/albums/h...install031.jpg
http://i547.photobucket.com/albums/h...install032.jpg

EGT's ? performance ?

I havn't run this setup yet

Gotta find some longer bolts, the 24v horn is a 1/2 inch or so taller

Does the 24v flow more over the 2nd gen 12v ? which ones better

From what I've been reading the 24v horn does flow more and it has a cleaner look too

So, whats the word on performance since you have bolts??? Are you going over to 97crewcab's to score the intercooler that came out of my brother in laws '99 24V or what? Your truck would be a good home for it......

Still gotta drive it, just got the bolts in about 5 minutes ago,

When I get some more funds I might go snag that cooler Todd's got, then I'll have every thing to intercool the old mans ride.

BTW will your bead roller roll beads on .095 stainless?

Well we got it figured out

had to do some minor adjustments on the throttle linkage, so now were getting full travel

at wot i'm seeing 40psi and 1400 degrees it takes a while to get to 1400 also, this is also the strongest the truck has felt, its breakin the tires loose in 4th gear[guitar]

sweeeett! does it smoke less? what was your WOT egt's before intercooler?

I didn't notice much reduction in smoke if any

EGT's before the I/C depended how long was your foot was into it, I could bury it in a hurry before

Well we changed a few things up again, we now have a 2nd gen I/C in the truck with 2nd gen plumbing

http://i547.photobucket.com/albums/h...install004.jpg
http://i547.photobucket.com/albums/h...install003.jpg
http://i547.photobucket.com/albums/h...install002.jpg
http://i547.photobucket.com/albums/h...install001.jpg

notice any improvement over the 1st gen intercooler? i have a 2nd gen cooler laying around, wonder if it would be worth slapping it in.

With the 2nd gen cooler I can still get it just as hot as with the 1st gen unit but it takes a while longer to get there. I did notice however that the truck feels more responsive and it seem like it spools a lot quicker

you could put some chicken wire or something in your grille slots and in between the filler and the bumper and Id be that'd look awesome :D

What year truck was that intercooler from?

Nevermind---I did NOT read everything [dummy][dummy]