Well thanks to junkyarddog I will be installing an intercooler setup from a 93 into my 90! Is there anything major that I need to buy? I know I'll have to do some fabricating obviously but I was just wondering about some basic things like if the A/c condensor needs to be the newer version or if i need different lines to it etc... Any help from the experienced would be greatly appreciated! Thanks
Dan

 

What parts do you have from the 93? What grill are you goin to use, the 90 or 93?

 

I'm going to use the 90 grill. The stuff included is all the mounting hardware to make it a "bolt on". Junkyarddog knows more than me what exactly is coming but im guessing the brackets etc... And all the piping of course. The radiator and A/c condenser are also from the 90. I'm guessing my stock fan shroud can be made to work?

 

Kiss your AC goodbye if you want to use the 90 grill. Barely enough room for the intercooler after trimming the grill to make room for the IC.

Also it's not a 'bolt on' unless you got the 93's core support and everything bolted to it.

The radiator and fan shroud have nothing to do with the IC add on. You just gotta use a sawzall to make room for the IC to pass through the core support- on each side of the radiator.

You're gonna need to fab some bottom tabs/mounts for the IC. I used some 1/4" steel bolted to the frame's crossover piece. Drill a hole in each tab big enough so the rubber bushing or leg of the IC will sit in. It will make sense when you get the parts in hand and have the bumper, grill and associated parts off.

Also for some reason the intercooler pipes will need to be lengthened. D-side about 3", P-side about 1-2" IIRC. You'll see.

 

When i did my first thought of an 91.5 and up i started by checking part numbers and non of them are the same
the compresser is a diff part number, the ac lines.condencer radiator fan shroud exc

will the old compressor and the newer ac lines actuly boltup? will the old ac lines bolt up to newer ac condencer?

never got that far!

looking at fig, how to put a 2nt gen radiator fan and intercooler in. I just haven't got my self into the details yet!

 

So are there any options other than a 91.5 and up grill then? Does Banks still make that one that they used to sell? Excellent replies by the way! Tell me everything you know

 

As far as I know banks doesn't make anything for these trucks anymore. But www.stullindustries.com makes one that is simular but I don't know if they mount the same or not. I have one and could take pictures of it for you if you would like but it would prob have to be tommorow

 

Banks make nothing for our trucks anymore ,also your 90 grill wont work and the 93 grill wont work you need a 91.5-93 core support and a/c ,and other coolers from a doner truck and i would swap in the intercooled radiator too.trying to swap in using 90 parts will take a lot of fab. work use all the 93 parts you can get theres barley room for that. I had a banks intercooler on 1 of my 90s and could not find a grill that fit right the banks tube grill was made to fit our trucks and its no longer made,you could fab a grill and have it chromed

 

i believe there is some type of banks grill in the classifieds. or at least was.

 

I did almost this same thing.
Except I changed the radiator also.
If you can't find a after market grill you wil have to kiss the AC good by.

I got all my hardware from the doner truck:
The mounting brakets for the intercooler
The bottom supports for the radiator
Stole the top mounting brakets for the radiator

If you go with the '93 radator you will need the fan mounting braket. (on mine the fan was more to one side and would not fit in the '93 shroud)
You *might* have some clearance issues with the master cylinder by extending the intercooler to intake pipe.
If you can't find a after market grill you will have to shave down the plastic part to make room for the intercooler and fabracate a braket for the center of the grill.

Other than that it is just a mater of cutting holes and welding every thing together.
It has been awhile since I have done this, but I think that is most of the major suff.

Good luck

 

Yeah I forgot to mention, the intake manifold cover plate, just flip it around 180* so you don't hit the master cylinder. You'll also have to tweak the injection lines to clear the grid heater and intake horn- or use intercooled inj lines.

 

Ok, I'll try and get a 93 core support and grill then, even though I really dont want to part with mine. O well, sometimes you just have to make sacrifices though These are excellent replies guys. Thanks a ton!

UNDERPSI Could you send me some pics of that grill you were talking about? Much appreciated!
sokkerdan@hotmail.com

 

You mean you actually have working AC? It didn't bother me a bit trashing all my non-working AC components.

 

Hahaha yeah my A/C works great actually. It should though, most everything has been replaced at least once

 

dont go nuts trying to find a IC core support just yet. wait til the stuff gets there and do some trial fitting. i was at junyarddogs house and I learned anything can be made to fit after seeing some of the conversions he has done. some pretty -some not- but all functional. I bought an old Banks intercooler kit for my 91(92 grille though) , the kit is for an 89-90 so I'm going to have a new tube grill (comes with kit) I wont be using either.
I need a new radiator so i'm going to buy the bigger I/C type anyway but i know i will be doing some fabbing. my A/C will remain one way or another. crossy