Billut

Hi all:

Because of the modifications involved with installing a PS or 2nd gen intercooler, I was wondering if replacing the 2 1/4" let in and let out tubes on the stock intercooler with 3" tubes would help in flowing a bit more air. With 3" tubes upstream and downstream.

What do y'all think?

Thanks,

Crossy's son

Sounds like alot of work if you're talking about actually modifying the intercooler so it has 3" inlet and outlets....unless you can weld aluminum at home i'd say its definely not worth it. THe surface area of the 1st cooler is not that good either.

3" tubes and stock intercooler seems like a waste to me if that's what you're talking about. that's like running a 4" downpipe into a 3" muffler then back to 4"

Billut

yep, I agree with you that 3" into a stock 2 1/4" is like 4" into 3" exhaust. Which is why I'm looking at welding 3" in place of the 2 1/4 inlet and outlet, so that it is 3" throughout.

So, my question would be more precise if I asked: with inlet and outlet modified to 3" and all 3" tubes, would the stock charge air cooler flow better? Could there be some issues - back pressure or else?

Crossy's son

It would flow better of course. You'd have no issues.

You may not get the gains you're looking for though, It'd be better to just do the modifying to get a P/S or 2nd gen intercooler to fit...

Its 2.5" BTW.

Philip

Crossy thats the outside measurement of the in/out. The extension itself is 3/8" thick. So that makes it 2.125" inside to inside.

From a WOT performance aspect. Increasing the in/out size won't help. The IC core itself doesn't have the flow potential.

Now if your thinking of more flow in the towing RPM range the 3" in/out does help on a stock IC. I noticed a 25 to 50 degree drop in EGT's at cruise speeds when I did the in/out on my IC.

If you do think about doing this.

#1 do not try thin wall tubing. That cut off stub is thick. It will take about 185 amps on a tig to hold a puddle. A thin wall tube can blow away so fast at that amp rating.

Here are a couple pic's.

Billut

Philip:
That confirms what I was thinking: I'm not looking at WOT numbers for anything on my truck, but at sustained load. I use the truck for pulling a gooseneck trailer with lumber, and if I see 100 degrees drop by having 3" tubes, a 2nd gen intake horn, I will be pretty happy.
Thanks to all for the inputs and remarks.

TRENDZ

I would assume it would help. It couldn't hurt. I was suprised at the second gen cooler I have. It uses 3.5" hose barbs, with an inner diameter of about 3", that transitions into a "D" shaped neck down that is HALF the sqare area of a 3" tube. I cut off the stock necks and welded on 3" tubes. I most likely came close to doubling it's flow with this mod.

Billut

Trendz: did fitting the 2nd gen charge air cooler require a lot of cutting and welding?

Crossy's son

wow all you guys happen to have equipment to weld aluminum? lucky...

Billut

I don't, but I have connections...

TRENDZ

Alot of cutting and welding? Thats sort of a realative question. Getting everything to fit behind the grille and lower grille sheetmetal was pretty intensive. I have an aluminum crossflow radiator that had to be modified to fit, build a new fan shroud, modified the cooler, mounted an A/C condenser(in front of the intercooler)
I have about 3 hours into modifying the intercooler alone. Not to bad.

Philip

I don't have a tig. I do have access to a tig. I didn't do those welds. That wasn't because I don't know how. It was because I can't weld anymore. My cardioligist kind of has fits when he finds out I am welding.

Crossy's son

<<<< (((((((googles cardioligist))))))))

Billut

Trendz: very nice but quite involved work!

Brandon: not sure what you're referring to about googling cardioligist, the second signature on the first post is the only one that popped at my eye...

TRENDZ

I always go beyond what is normally accepted. The minor tweeks here and there seem to add up to satisfaction later. My own personal motivating mottow is " If the only reason you're not doing it that way, is because it's difficult... Than you have no excuse not to.