Just found out my intercooler has split tubes. Crap! This turbo job is getting expensive.
Now I have to decide if I want to chance a stock unit with 40-45 psi or fork it out for a heavy duty one.
I dread informing my wife!

 

Best performance for the $ might be make a 2nd gen '94-'97 intercooler fit.
Check out the sticky for a write up.
I did roughly the same swap on my '91.0 and black crew cab using 2nd gen intercoolers. Once I used a '98-'02 intercooler which is about and inch taller and it was more difficult to fit in. Which is why I recommended the '94-'97 12V ones.
I used all the 2nd gen pipes, clamps and boots too, along with a 2nd gen intake horn. Bonus is they are much larger and flow much better than the '91.5-'93 pipes.

 

I hear the Ferd 99-01 7.3's work better on a 91.5-93 truck, maybe I should go that route. I can't even find a 1st gen one for less that $800. The radiator shop sold me one for $375 and it turned out to be a 2nd gen, which would require a lot of cutting... He is looking for a 1st gen now.
Fiasco.

 

Good news, they found a heavy duty core upgrade and are going to install my tanks on that core for the same price (he's a friend of mine) so I am stepping up heat transfer capacity and getting a 200 PSI tolerance.
Feel better now.
Next time, I will go larger!

 

I put the power stroke intercooler on mine but have never seen anything even close to the turbo pressures your have...max I've managed to squeeze out of my motor is 25 psi. But is sure does keep my EGT's low even when pulling heavy in the middle of summer.

 

This truck is unreal. It is way quicker than it should be with a VE pump. I'm almost glad the clutch is messed up, because that keeps me from racing it. With this new wheel and intercooler, 45-50 psi will make it even more deadly!

 

Pushing 45psi, it's just a mater of time for me. I tried doing the ford IC, but could never get it done with all the work involved and people kept messing with me so I wound up abandoning all my projects. What is the easiest IC upgrade for a 1st gen?

 

The general consensus is the 99-01 7.3 Intercooler (metal tanks) for the 91.5-93 trucks, and 2nd gen IC for 89-91.5

 

I abandoned the ford IC idea because it was way too much fab work for no time or place to do it. Where did you get the heavy duty core from?

 

Local place. I will get the info for you.

 

cougar,
I like the 2nd gen '94-'97 I/C on '91.0 core support that uses the earlier radiator but has the latter style grille over it for more room for the I/C. The earlier style radiator is more than enough to cool my stick shift trucks as the auto trans. is not dumping all its heat into it.

That is my favorite way to do it, but I have several of all the year 1st gen core supports, radiators, fan shrouds and 1st and 2nd gen I/Cs on hand to choose from.
Ford parts don't exist in my shop.
There are some pictures of how I did it on my Saving a '91.0 W-250 thread.

 

Why would they?

 

I have the radiator and intercooler from a '99 Dodge in my '93. It was all bolt in after I got done modifying everthing.

 

Got my upgraded CAC back today, good to 400 PSI.
Now I can finally go test my upgraded 62/86mm compressor (as soon as it isn't 96 degrees outside).

 

Looks good.
What does the wife say about car parts on the carpet?