Well, I must say thank you to all of you that were kind enough to post step by step pics of the install, and a special thanks to Ace, for responding to all my phone calls. My install went smooth, and being a sheet metal worker by trade, I was able to design and fabricate special brackets to properly mount the intercooler, along with using a material called isomode, for flex/isolation purposes. I did lose the stock center post like all here that performed this mod, but was able to design a 25" long channel that reconnected the hood latch "shelf" and tie it in to the structure under the radiator. My grille required no notching whatsoever, infact, I have a 3/8" clearance from intercooler to the back of the front grille at every area. I did notch 3/8" on the painted piece below the grill, but only for a 1 1/2" long stretch on each side, where it touched the intercooler sides. My AC condenser coil is a 1/2" away from the black sheild metal that is in front of the radiator, and the AC coil is also on the isomode pad for vibration isolation. I even had room to screen the intercooler with 1/4" galvanized, painted black, wire mesh/birdscreen material to protect my investment from rocks and large bugs. I am still in the middle of connecting my cooler tubz plumbing, and also in the middle of relocating the factory ATC cooler ( I have the A518 auto) and its in/out lines. I'll let you all know on the driving differences once I am done. Again, thanks to all!

 

It is 2am CA time, and I just completed the Worline Coolertubz install. What a slick upgrade! Perfect fit up, nice bling. I had 4 stainless npt bungs tigged on for my water injection nozzles and my Hobbs switch. All I have left is the relocation of my factory tranny cooler which originally sat on top of the stock intercooler. I will mount it vertically in the space to the right of the new intercooler, behind the grill and in between the drivers side headlight and the intercooler. Should work, and should still get airflow. Sorry about no pics. I am an when it comes to the pics.

 

Sounds COOL!!! I've been wanting to do this to my 92. Got any pics?

 

pics pics pics pics

 

I don't think he has any pictures.

 

someone pm me a step by step on pic downloasding!

 

Took it for a spin this evening. There definately is a difference that you can feel. Truck does not jump as fast on the boost, as expected, but the pull at 25 psi boost is awsome. The engine idle noise is different, too. Seems that the internal moving parts are more pronounced. Sounds cool! I would definately do this mod again if I ever landed another 1st gen!
On the downside, the truck still smokes at full throttle. I thought more available air would tame my pods down with the smoke.

 

So you replaced your stock intercooler with the 7.3 intercooler? How much did it lower egts?

 

From the sticky: https://www.dieseltruckresource.com/d...d.php?t=187910

I think your boost should be a little higher since you have a non leaking intercooler and new boots I just checked my Intake plenum gasket (under the toaster grid) and it was ripped and blown out in many spots. I could only hit 20 psi before. New injectors and I saw 25 a couple times, now I can't get above 15psi for long, it drops off pretty quick.

 

The EGT's actually run hotter quicker than my stock system did. I used to work hard to get to 1000 dgrees on the pyro, and now it seems like it doesn't take mch effort to hit 1000 degrees.
On a positive note, I notice it takes less effort on the pedal to get the truck moving. Seems like now my 0 to 60 mph is achieved a lot sooner than before, and it takes way less effort to hit and hold 30 psi boost. I will definately keep all of you posted on my miles per gallon readings, just as soon as this new found power excitement wears off and I can press lightly on the pedal!

 

I think you have a boost leak.

 

I changed out only 1(top) of the grid heater gaskets with the coolertubz install. The bottom gasket between the grid heater and the manifold olate still looked inyact. These gaskets are OK to reuse if noy torn, correct? Other than that, all boots, spring clamps, o rings, are all new. The ps IC still looked like it onle had 10,000 miles on it.

 

there is another gasket UNDER that, I didn't really notice it either! The intake plenum has an aluminium cover with 2 sensors screwed into the top of it on the after side of the engine. The grid heater is screwed right onto it. It has 14 bolts if I remember correctly. I did a search on it, and it seems to be a common problem! I ordered the NAPA brand ($7) gasket, and I intend on using an adhesive (prob not silicone) as well. Mine was bellowed out, cracked, and just not good in many spots once I got the cover off. It will be easiest to remove at least the forward set of injector lines. You can get it out without doing that, but I think I'm gonna remove mine to put it back in and make sure everything is in there right.

 

You're going to have to pressurize the system and soap it up. It makes no sense that your EGT went up with a bigger intercooler and plumbing with no other changes. Everybody else sees a drop (which is what is expected, and the whole point of the exercise).