Well, before I pulled the core support, I had to finish up the trimming and precise fit of the new intercooler... The only thing I will have to address is the trans cooler.. But that is no biggie!!

I looked at the doing it how it was done in the sticky and I was having trouble clearing the inner fenders.. So I decided to flip it upside down.. And it worked awesome... I slipped the A/C condeser right in between the intercooler and radiator with about 1/2" air gap.. Other than that, I have to finish up the plumming, but that will have to wait untill I get the core support back from the paint shop...

 

Nice clean fit. Lookin good.

 

So...has anybody else down there's like this?? I see alot of powerstroke i/c's but not many 2nd gen's... Do they both offer the same benefit, or is one better than the other??

 

i think mose people put them the factory way so they can buy tubes that fit easier,
the ps and 2nd gen intercoolers are almost the core size but the ps has a better tank setup, on a 2nd gen the outlet side (your inlet side) has necked down area where the ps one doesn't.

and the powerstroke ones arent painted with heat attracting black paint.

also ford parts are easier to get since they dont stay running

 

Hmm.. I was looking at the inlet/outlet tubes, there like 3.5" oulet but are choked down just before.. I was thinking of cutting them off and welding on some free flowing ones... I wonder if I can get the tank dipped in something that would take the paint off and give it the raw aluminum look??

Reason I went with the 2nd gen is because I got it for free and I didn't want any ford parts on my truck!!!!

 

i dont think the choke down matters that much, you could probally use normal paint stripper.

i think the 2nd gen is fine i used a powerstroke one because i didn't know 2nd gen would have fit easier in my factory non intercooled truck and the local wrecking yard had one the day i wanted one.

 

If that 2nd gen IC is like a first gen IC. That isn't paint. It is powder coated.

 

I bet "aviation paint striper" would get rid of it.

Nice job on the install, looks very nice.

Too bad they are so friggen expensive, but an aftermarket I/C has way better tanks on it.

Anyways, awesome work.

 

Wow!! Awesome pics. I have the same intercooler waiting to go in my non IC truck as soon as I can make time. I was debating doing exactly what you did. Thanks for the reassurance. Keep the thread going so I can see how you plumbed it all up. I was thinking of facing the intake horn towards the front of the motor.... Any ideas?

 

Soooo Ive read a few of these threads about a 2nd gen I/C install....(nice pics BTW)

Seems that most doing it are none I/C trucks........I get the fact that they are doing it because they need an intercooler but does having a non I/C core support help any?

I didnt think there were any differences between the two.......one with holes and one w/out.......

 

the reason for useing a 2nd gen i/c on a non i/c'd truck is too clear the radiator/mounts.
a powerstroke i'c will fit around the stock rad in an i/c'd truck

 

Yup. You have to cut lots to get a powerstroke cooler into a non i/c truck. Been there done that.

 

or you cut the intercooler, done it.

 

Guys, I don't know if many of you noticed, But I ran mine upside down for say compared to the norm... And let me tell you, I think that is the ticket.. I don't have any crazy bends, plenty of room to work... All I had to do was make a new battery tray... The only thing I don't like is how the inlet and outlet is.. They have a funky knecked down area... I think that was the second best mod behind the 47rh...he..he!!

 

I know Pacool and I did the same thing on the powerstroke cooler. I had mine one way and he had his the other.