1993 w250 single cab 5 speed. Scheid diesel hot rod 12mm pump, 20* timing at engine pump is set at zero, 5x14 injectors, 091 fuel lines, s300 57mm turbo, arp studs, fire ringed head, 3" pusher intake system, south bend single disk clutch.

Thinking i wanna do a 7.3 cooler swap guys. Making around 400 hp to the wheels right now. I was looking at 7.3 intercooler and i found a oem replacement on xtreme diesel for like 250 bucks. Sounds great compared to the big name upgrades for 900 at the least right??? My question is how hard is this swap? AND are the expensive big name coolers really that much better than a oem coolers?? Would it really be worth it (with power and performance in mind) to spend another 800 for a big name cooler like afe or banks??
Thanks everyone

 

Old bull, it's not a hard swap, as long as your methodical in the steps of the install. Being mechanically inclined helps, too. It took me a weekend to install, taking my time, but for two weeks prior I had already built it in my head, while gathering hardware and building the different steel brackets at work. If you like to measure, this is all about that.
Having a hand plasma will help as you will have to enlarge a few openings in the core support.
Use the search feature and type in powerstroke intercooler, and you'll get all kinds of treads on it, or you can access the Sticky and look at ACE's install. He did a great job, with step by step pics

 

Last thing- go to a diesel shop, that does performance upgrades for clients wanting to swap out their OEM parts. You can pick up a stock intercooler that's sitting out in the back for around a hundred bucks like I did. Make sure it's one off of a 1999 or 2000, with the aluminum sides. The 2002 years had plastic sides.

 

Stay away from the PS IC with the plastic side tanks....as long as it's a solid aluminum unit you will be fine. Some reason not to use a stock unit?

Take a look through my build thread, I installed one on my crewcab during the 4wd conversion....I didn't need to modify the rad support much at all, just had to use a drum sanding disc to open up the area the stock 1st IC tubes run through.

 

will do thats not a bad idea, so not really any performance difference between stock and aftermarket?

 

I'm thinking on my last reply to you I wasn't clear or failed to explain correctly- my bad. I found a used intercooler(IC) at a Diesel Performance/ repair shop. I called around, asking if they had an IC off of a 99-2000 powerstroke sitting around. He did, and sold it to me for $100. The previous owner of that IC had a Banks one installed.
Yes, the powerstroke IC is a major upgrade. Way more air allowed to be pushed thru the IC system.mthe stock IC is way smaller, with 2.5" inlet/outlet, while the powerstroke is taller, and has 3" inlet/outlet. If you do the whole shebang and change out your IC piping to all 3", you'll take full advantage of what that IC has to offer.
Just trying to offer suggestions to save $$ is all. If you have the $$, have a custom one made like BC847 did, as it basically look like it grew on our trucks. No hacking, a true bolt in.
I made mine a true bolt in with no welding involved, but I had to make custom brackets. Also, I ended up mounting it in front of the A/C condenser coil, due to its size. BC had his mounted in the stock location