Update....removed the coolant line from the aux tranny cooler to the water pump. Cut a 6-7" piece of metal tubing off of it to join the new hose to the factory 90 elbow. Routed it around the turbo oil supply line and hooked it up to the aux tranny cooler and refilled the radiator. Finally got the new/used turbo back on. Looked into the I/C piping and saw it was covered in oil.

So took the front end apart and got the I/C out and looked into it. Sure enough it has oil residue in it. Going to have a buddy wash it out tomorrow then put it all together again and see how it all works.

Sorry for the poor picture

 

Looks like you are on your way.
This is the type of thing that happens to me. I have a knack for finding the only odd ball part that exists and causes a total redesign.

 

Cactus, build yourself a home brew boost leak tool out of Home Depot plumbing parts and check for leaks. This one is made to attach to my Hybrid HX35 compressor inlet. You can isolate different parts of the system by capping them off at certain spots, like in your case you may want to check your intercooler for leaks. Heck, you can build one of these just for the intercooler itself if you choose.
It's a crude design, but cheap. If I did this more frequently, I would outright buy one from Bob Riley at dieselsite.com, as his design is in my opinion the best as far as build quality.
I believe 15-20 psi is all that's needed. I would go to your local HVAC supply house and get a true leak detector spray solution vs. home brew concoctions.

Lastly, check your exhaust down pipe to see if there's oil mist residue on that, also. Might as well.

 

Well big, that looks like a pretty slick tool. It was only leaking on the cold side. I did check the downpipe and she only had soot, no oil thankfully.

Mknittle, well if I didn't have bad luck, I'd have no luck at all

 

Just some of life's little challenges
Infact I am going outside after lunch to have some more fun I may even get something done.

 

You guys with intercoolers

 

HA! We got big lungs!

 

 

Mknittle we all can't be as cool as you non I/C guys.

Just got her buttoned up and cranked her over. Runs like a champ now and a louder whistle than the H1C. Just need to finish it off with a 4" exhaust band clamp to make the 2 pipes 1 again. Thanks for all the help guys

 

Glad to hear that. I am putting together a HX for mine too.

 

Wonder how a hx40 would be on your setup? Is a 40 4" v-band? Have to ask you what a hydroboost is

 

I will probably swap the HX35 compressor for the Hx40. The Hx40 does have a 4" outlet.

The Hydroboost is a brake hydraulic brake booster that runs off of the power steering pump. They are popular with first gen guys to eliminate the problematic brake master cylinders. The side effect is much better brakes and better pedal feel. Some guys adapted the 2nd gen others like me used Chevy.

 

I know my next project for the 250 is brakes. Might as well redo the whole works except for the lines......if possible. I'll have to do some research on hydroboosts. They sound like they are 10x better than the factory braking system

 

Add this to the hydro boost and you will be surprised at how good the brakes work.


https://www.dieseltruckresource.com/...-brakes-63137/


Just be sure to wear your seat belt on the first drive. tons of hydroboost info here.

https://www.dieseltruckresource.com/...got-em-169715/

 

One of these days, I will bite the bullet and add HB. Already have the 3" shoe and cylinder upgrade. But first, body work and paint.
Sorry, Cactus, didn't mean to hack into your tread and start talking about my needs, LOL.
On your trucks air supply- have you researched at all on a powerstroke intercooler retrofit? That, along with new 3" piping to and from the IC all the way to the combustion chamber/intake plenum is the cats meow. There are a couple of how to's in the sticky. I followed the one done by ACE.