Alright, you do have to cut the frame horns off, i welded a channel iron to build bumper mounts and build my frame up and built a "trough" for the 3rd gen intercooler to sit in, i capped the ends and bolted the bumper horns to the outside. I then just widened the bolt possisions of the bumper in porportion to how much i had widen the mounts and drilled the bumper. The the holes for the inlet and otlet are in the perfect spot, my intercooler is level with the bottom of the frame, i cut 4" holes in the core support for the boots, you cant use a hood saftey latch, the top angle brace where the hood latches has to be trimmed for the top of the intercooler, i trimmed the intercooler brackets completly clean so there was nothing but intercooler and no factory brackets. with a cut off wheel and buffed it smooth and painted it. tougher than the factory. i cut a rubber mat for the bottom of the inter cooler and it sits loose in the trough and i built simple brackets for the top. the grille and valance dont need to be trimmed, i didnt have ac or a tranny cooler to worry about. i pretty sure that my intercooler is not going to come out of its hole with out taking the whole front end apart.

and yes its magical

 

I would rather not do away with my hood safety latch though. Maybe I will just go the Power stroke route. It should be plenty big enough for what I am doing anyway.

 

good idea, as much work as it was, im more than happy with the results, its nice not watching the pyrometer now and then.

 

My buddy is parting out an '03. he wants $150 for the cooler, so I might go to work and shorten it, or cut apart my bumper mounts. I'll jump off that bridge when I get there. lol

 

Nice!

 

Scratch that it's $250 for the cooler. What do you guys think. I still have to cut it up and have it welded. What would scooby do?

 

scooby would buy my stock IC and pipes. LOL

 

Sorry man. I'm trying to loose the "stock" idea, a little at a time.

 

You could get a PS intercooler for $75 to $125 i bet and it'd be a lot less work and it would do the job well

 

I will have to look around for one then. Thanks Austin.

 

Yeah i priced one for $125 at a local scrap/semi/truck junkyard so i bet you could find one for about the same. I plan on upgradin mine to that soon too so i have full 3" all the way through.

 

I was actually kinda thinking about paying it, if I could get the intake horn, boots, clamps and all the tubing.

 

for the 3rd gen intercooler?

 

right $250 for it all. Found an intercooler for a 99 ish powerstroke with all pipes for $100, but it's in Louisville Kentucky. Don't get down there very much. lol

 

Yeah i guess it'd be a pretty good deal if you got all the pipes, intake horn and clamps. I'd say go for it.