adding an intercooler

fnelson71 · 03-10-2015, 10:00 PM

ok im going to build a custom front bumper and i want to add an intercooler. i found several intercoolers priced from 60 to 120 on craigslist.

so my question is how do i install the intercooler.

bansil · 03-11-2015, 03:42 AM

What kind of:
Bus
Engine
Why do you want intercooler/after cooler etc
Air to air?
Are you sure you don't have one

They cool the air before it enters the engine, say like from a turbocharger outlet thru cooler into intake

So you need a bunch of elbows and straight pieces of metal alum or steel tubing sized to turbo/engine and rubber or silicone connectors

And be careful about those cheap intercoolers, they are probably to small

Just stuff to think about

fnelson71 · 03-11-2015, 05:48 AM

2001 ford e450 7.3

sdwarf36 · 03-11-2015, 06:15 AM

You might want to go check out the van section over at DIESELSITE - DIESEL MAINTENANCE and PERFORMANCE
There's a many page long thread of people (who have tons of experience and love to work on their vans) who have tried/want to put on an intercooler. I've only seen one done-at great expense-a water cooled one mounted underneath. Severe lack of space is the problem.

Tango · 03-11-2015, 10:48 AM

Ya...I should have noted that there are two basic types of intercoolers...aka; Charge-Air-Coolers (CAC for short):

Air-to-Air...&
Air-to-Water.

Air-to-Air is fairly simple in that you just hang an extra "radiator" type element and connect the piping (turbo to CAC - CAC to intake).

The Air-to-Water gets quite a bit more complicated in that it calls for same the air piping PLUS all the water connections to the CAC itself.

Definitely look around online. You will very likely find that most of the work designing and putting together a system have already been done many times.

Best of luck...go for it.

cowlitzcoach · 03-11-2015, 01:20 PM

Outside of the cool factor I am not sure exactly what you are trying to accomplish.

Eliminating the OEM air intake for a cold air intake with a freer breathing air cleaner will do almost the same job for a lot less $$$ and time invested.

Banks has plug and play kits available for cold air intakes.

Banks also has kits available to warm up the 7.3L that would be a lot easier to do than an intercooler.

The increase you would get out of an intercooler would be minimal IMHO for the investment.

sdwarf36 · 03-11-2015, 10:37 PM

Cool is the word-to cool down the EGT's.
An intercooler cools the air after it been spun up + compressed (and heated) by the turbocharger. And hot air into the engine = hot exhaust out-why exhaust temp is measured.
Fresh air intake just takes air from somewheres else -and then plumbs it before the turbo.
I come up to a hill on cruise control-and just holding 63mph-my boost will go up to 12-15-and the EGT's shoot past 1300*. I have to shut off the cruise an roll out of it--10 psi puts it around a safe 1150-1200. And if its a long hill, I'm now in the slow lane dropping speed. If it was intercooled, you could probably do 18 psi boost before getting that hot. Not that I would need that much-but it would be nice not having to lift on hills.

A fresh air intake might help free up a few HP, but that will come at the expense even more heat.

Tango · 03-12-2015, 10:08 AM

I'm no diesel tech by any means, but when I was having my 4BT Cummins rebuilt by Diesel Specialists here in the Houston area, I asked them if the CAC was really necessary. They said no...not "necessary"...but that I could expect a drop in both HP and MPG of as much as 10-15% without it plus a "considerable" rise in EGT.

The front end configuration of my '46 Chevy makes the installation tricky but based on their input, I am definitely going to install one. And since the original is much too wide, I am looking at having one made up that conforms to my narrow but tall front end.

EastCoastCB · 03-12-2015, 03:46 PM

Anyone have any experience adding one to a DT466?
I think if it help one iota in the steep stuff it would be worth it. I'd even be willing to possibly upgrade the turbo as well if really needed. I'd just like better power on grades and would be willing to spend a few bucks.

nat_ster · 03-12-2015, 07:45 PM

Quote:

Originally Posted by EastCoastCB

Anyone have any experience adding one to a DT466?
I think if it help one iota in the steep stuff it would be worth it. I'd even be willing to possibly upgrade the turbo as well if really needed. I'd just like better power on grades and would be willing to spend a few bucks.

Most the DT466's here already have a combined intercooler / radiator.
They work like crap.

Better would be to pull one from a TC2000 FE with a 5.9. It would bolt in with only a few tabs to hang it.
The TC2000 intercoolers are massive, and Intakes are the same size as the DT466, so no loss in flow.

Nat

Tango · 03-13-2015, 12:16 AM

You also need to make sure there is not a significant drop in pressure throughout the system. As I recall, something like 3% or so is what to shoot for but there are probably better minds than my own here on this part of the design. The CAC that came with my little 4BT is ginormous but tailored to the engine. I plan on having a custom built that matches it in terms of volume and area but is vertical rather than horizontal in layout. I need to do more homework before spending any money.

EastCoastCB · 03-13-2015, 04:15 AM

Mine doesn't have one at all, and lots of them don't.

Tango · 03-13-2015, 09:57 AM

Not at all uncommon and they run just fine. The CAC does improve overall performance a bit and helps quite a bit to keep down the EGT's under a load or up a hill.

The effect of cool intake air can be surprising and really shows up on two-cycle engines. I used to race 2-stroke Forumula bikes and on days when we had "cool, fat" air...the difference was pretty amazing. And sweet. The added density is sort of like raising the octane of the atmosphere.

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