intercooler install on way - Page 2 - Diesel Forum

VISIONQUEST · 10-22-2009, 09:09 PM

RPM intake im using is http://cfmplus.com/ works fine goes right on i got a scratched up one from them they gave me a little dicount now it will fit 01. i know that older models have a 2.5 it wont fit you would have to get the intake of a truck or just change your intake ports to bigger ones . and yeah your right intake got to be pipe + connector vacuum sucks silicone closed .

dansk there is a little room when yyou get ridd of BS in there

arz, im using a W/A kinda large its going to go were air box was same hieight and width a little deeper , as far as A/A intercooler goes it can be done you would have to move battery to frame and cut some holes on front and measure for size . dont no but you might need alot of patients lol.

currently im kinda stumped been ^%&^*& with this for days trying to just have a complete intake circle for testing purposes but the piping will not stay together , now i know what they meen by pipes blowing off i have a peak around 38 lbs i finaly took it off and laid it on ground and pumped air into it it swells up like a K2 football , when it swells up there is not enough room in the when installed in motor bay, so im going to try to get some pipe mandrel bent
i only need a couple peicies here is some picks with no air and 30 lbs in the pipes any more pressure it would have blew apart . im in kinda deep in this and ima gettting alittle pissed they fail to mention silicone piping realy isnt good over 20-25 lb when you by it but im bighting my tongue , i can get through this, im persistant , maybe i just need some cheers and some R&D cash !

VISIONQUEST · 10-22-2009, 09:18 PM

pictures

rpm1 · 10-22-2009, 09:54 PM

R&D gets expensive and time consuming!!!! Buy your own mandrel bends and tack them together. I am not a very good welder and that is what I am doing. Then I will get them welded up by somebody that can make the piping look pretty.

And there are much better clamps available for silicone to metal tube. They can get pricy though! Good Luck!

VISIONQUEST · 10-23-2009, 03:25 PM

rpm : I dont own a welder (yet) but yea that sounds easier but you still need edges on the pipe to stay on the clamps
anyway i got a company neer by that has a mandrel machine and there going to digitize my silicone pipe and hopefully make pipes they can only do steel no aluminum , so im going with aluminized steel , if its stronger i got to talk to them monday , have you started your project if so start a thread and post pics so i can see what your doing

VISIONQUEST · 11-08-2009, 11:38 AM

I just got SS pipes fabricated by a mandrel pipe shop neer me, they hooked me up , we decided to with the SS because , well a buch of reasons ,they had to tig weld them together from my silicone pipe mock up , to short for mandrel bending to close of bends , but any way i got the intercooler mounted and im checking for leaks etc so far i just went for ride and hit 32 lbs,and WOW it dosnt fly apart im happy , before it went to 38lbs so im going to do a manual air pressure test and see what this system will hold (make sure im not losing air some were like every where before .

I would immagine i would loose some pressure do to volume of space i have to fill now ??? vs going directly in from turbo to intake ???

anyone,anyone, ferris?

**SmokeyWren** · 11-08-2009, 07:26 PM

My last E-van experience was a '77 E-150 window van with privacy glass, converted to a luxury family wagon with four Flexsteel Captain's Chairs. It had a built in high-density-foam mattress behind the seats, covered with luxury deep-pile carpeting. It had a 351 Cleveland motivator, and a seperate sterio for the kids in the back with headphones but no speakers.

I put over 100,000 miles on that puppy, then sold it to a neighbor who put another 150,000 miles on it - last I heard over 20 years ago. So I don't know anything about the recent E-vans, but that one was a good 'un..

But the stock turbo (with so-called intercooler which is technically a charge air cooler) on my '99.5 SuperDuty pickup is limited to a max of 25 PSI. Else the turbo tends to go south well before it gets to retirement age. So with a stock turbo it probably won't hurt to test your intercooler tubes at higher PSI, but when you begin driving it you should drive by the boost gauge and never exceed 25 PSI.

VISIONQUEST · 11-12-2009, 03:05 PM

Quote:

Originally Posted by SmokeyWren

My last E-van experience was a '77 E-150 window van with privacy glass, converted to a luxury family wagon with four Flexsteel Captain's Chairs. It had a built in high-density-foam mattress behind the seats, covered with luxury deep-pile carpeting. It had a 351 Cleveland motivator, and a seperate sterio for the kids in the back with headphones but no speakers.

I put over 100,000 miles on that puppy, then sold it to a neighbor who put another 150,000 miles on it - last I heard over 20 years ago. So I don't know anything about the recent E-vans, but that one was a good 'un..

But the stock turbo (with so-called intercooler which is technically a charge air cooler) on my '99.5 SuperDuty pickup is limited to a max of 25 PSI. Else the turbo tends to go south well before it gets to retirement age. So with a stock turbo it probably won't hurt to test your intercooler tubes at higher PSI, but when you begin driving it you should drive by the boost gauge and never exceed 25 PSI.

thanks for the info
well im not sure but i think the 99.5 F have the blow off valve set at 25 PSI from factory the vans dont have this valve this is why the truck guys want the van turbo housing , iv been told the 7.3 PS is good to 44lbs then it starts blowing head gaskets , im going to do a pressure check asap

rpm1 · 11-12-2009, 07:48 PM

It's not a blow off valve, it's the wastegate. But the main reason the van turbos are desirable is that is has a 1.15 turbine housing vs. the trucks .84. Lose a little off the bottom, but more than make up for it on the top end.

When you get this intercooler done, with all else being the same, you will lose boost, but make more power. The cooled air takes up a lot less space, even though there is more of it.

VISIONQUEST · 11-12-2009, 08:15 PM

Quote:

Originally Posted by rpm1

It's not a blow off valve, it's the wastegate. But the main reason the van turbos are desirable is that is has a 1.15 turbine housing vs. the trucks .84. Lose a little off the bottom, but more than make up for it on the top end.

When you get this intercooler done, with all else being the same, you will lose boost, but make more power. The cooled air takes up a lot less space, even though there is more of it.

Right waste gate/blow off valve they both do the same thing over boost regulated pressure relief , just like a radiator / heat exchanger just a different term , I’m not positive I should be losing and boost were not talking very many cubic feet of air, hoses /pipe are very short , and right now I don’t have any coolant running through it , but still I knocked off a 1/3 a second off my ¼ mile lol , I’m currently looking around at heat exchangers and cir pumps etc

rpm1 · 11-13-2009, 08:58 AM

Yes, a radiator is heat exchanger, but a blow off valve is not a wastegate.

When I say boost loss, I mean in a good way. After intercooling the air is much more dense, so more air taking up less space is going in the engine. Hence, less psi, but more power. More power at a lower boost level is a good thing.

After you get this done, it would be interesting to see before and after either on a dyno or at a drag strip.

BlizzardVan · 11-15-2009, 08:20 PM

Quote:

Originally Posted by VISIONQUEST

pictures

Nice work on a tough project. I noticed in your pics it looks like there is some engine oil on your plumbing. If you haven't already done it you may want to plumb the crank case gasses out the back of the vehicle vs into the intake. It will help keep the intake tubes from blowing off.

VISIONQUEST · 11-18-2009, 09:24 AM

yeah thanks for the advice blizzard, i actully have it vented out the back and down under , im probably going to do the green thing and run it into a catch can , I think you were seeing the black adhesive i tried to use on silicone pipes to hold them together , it worked up to about 25 lbs then they would come apart they are good for low pressure systems , and of course i couldnt return them because they were used , selling them on ebay with left over parts , I did use a 45, and a 90 the rest is now stainless pipe , works great this is going to be a slow project , im looking for the largest heat exchanger now or maybe use two not sure but intercooler is bolted up and intake is running through it ,iv gotten along way with this in my opinion already. Iv been wanting to do this sense 01 lol

VISIONQUEST · 03-23-2010, 10:08 AM

Just a update never finished intercooler because I had lots of trans problems , So i paid a rebuilder and that worked out terrible , So now im rebuilding trans myself first trans rebuild , I picked one up used at a junkyard and im rebuilding it and throwing it in , I am a mechanic but not a transbuilder so its a learning exsperience .. Wish me luck lol

clev · 03-24-2010, 08:34 PM

I read somewhere that the 6.0 (I think) had an integrated radiator/ac condenser/inner cooler combination that should just drop in. Anyone heard/read anything about that?

djtho1 · 03-24-2010, 10:00 PM

Can't wait to see how this turns out, once the tranny rebuild is done. Some of us tow with these things, and an intercooler would be huge. Mine will climb like a scared cat for about a mile with the camper on, then the EGT comes up, EDGE starts pulling fuel, and things go flat. If it works for you, I would think several people would be interested in a kit.