Intercooler comparison, side by side - Ford Powerstroke Diesel Forum
6.0L Performance Parts Discussion What has or has not worked for you?

 37Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 88 Old 06-01-2014, 11:39 AM Thread Starter
Compression Ignition Addict


 
madpowerstroke's Avatar
 
Join Date: Aug 2011
Posts: 1,515
Thanks: 2
Thanked 33 Times in 23 Posts
Mentioned: 0 Post(s)
Quoted: 0 Post(s)
Feedback Score: 0 reviews
Intercooler comparison, side by side

Hello, members and 6.0 powerstroke owners.

Members know me from building turbos but this thread is not going to be a sell pitch for them but to help all turbo make power efficiently. I did started turbo building a while back and have been busy so I have not been able to do the things I like to do the most, which is testing, side by side comparison, to help out other 6.0 powerstroke owners, and give them some information to help them make a decision on products for their trucks.

Now that I finally have gotten my test truck back, I can start to do the testing I wanted to.

I will be comparing as many air intercooler as I can, how do I plan to do it? here is the plan, I will be doing real testing, I will be welding some buns to my intercooler pipes to fit air temp probes in them. One probe will be installed just before intercooler and the other right after intercooler. I will be using stock intercooler first and collect the data on temp. differences. Later I will be switching to other intercoolers, Banks first since I have that one now, then Spearco, and so on. The intercooler pipes will remain the same as with the turbo,and intake as to keep this as even as possible.

I believe aftermarket intercoolers do make difference, but don't know for sure. It would be nice to know if the intercooler makes a difference or even worth it before spending money on one. Other then the stock intercooler made with plastic end caps, does it do the same job as a aftermarket one? I know that the cooler the air charge going into the engine, which is also giving you dense air, which means it has more oxygen it will produce more power. But what I don't know is how much better do after market intercoolers work and which one is better. I also know that this is going to be on my truck so some results may be different depending on combination of parts on other trucks, but will give some sort of in site of efficiency of the intercooler.

There are other reasons for the testing I will be doing but I will not go into that yet. This is a first of many threads I plan on starting with some really crazy things I have plan. I enjoy doing this sort of stuff for my own knowledge and to help others. I will not be doing dyno testing with the intercoolers since I don't have a dyno that is available to me, but as stated before the cooler charge will equal more power.

Thanks,
Patriot and john galt like this.
madpowerstroke is offline  
The Following 2 Users Say Thank You to madpowerstroke For This Useful Post:
Brew_WY (06-02-2014), Canadian Mind (07-19-2014)
Sponsored Links
Advertisement
 
post #2 of 88 Old 06-01-2014, 01:16 PM
Premium Member
 
Ford_Fan1's Avatar
 
Join Date: May 2013
Posts: 1,425
Thanks: 11
Thanked 53 Times in 49 Posts
Mentioned: 1 Post(s)
Quoted: 6 Post(s)
Feedback Score: 3 reviews
That sounds great! I am very excited to hear some results.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

"Pickle Monster"
2004 F-350 King Ranch built 3/24/04
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

4" lift, 5" MBRP TB back exhaust
EGR MIA
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
,ported intake, 05-07 intake horn
CCSB
FX4
Firestone airbag suspension in the rear with on-board compressor
Monitored with Edge Insight CS, tuned by Gearhead
high idle mod, Atlas 40 FICM tune, Cat ELC,
2008 taillights, 08 mirrors, smoked marker lights, harpooned fuel tank, DIY headache rack, Bushwacker fender flares
Ford_Fan1 is offline  
post #3 of 88 Old 06-01-2014, 01:33 PM
Compression Ignition Addict
 
MrOneEyedBoh's Avatar
 
Join Date: Sep 2012
Posts: 2,745
Thanks: 45
Thanked 144 Times in 78 Posts
Mentioned: 0 Post(s)
Quoted: 13 Post(s)
Feedback Score: 11 reviews
In on this..


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
MrOneEyedBoh is offline  
post #4 of 88 Old 06-01-2014, 06:04 PM
Premium Member

 
portcity_gt's Avatar
 
Join Date: Apr 2008
Location: shreveport, la.
Posts: 7,036
Thanks: 4
Thanked 349 Times in 315 Posts
Mentioned: 58 Post(s)
Quoted: 1085 Post(s)
Feedback Score: 0 reviews
I welded the bpd tank kit on my stock cooler and for sure lost 100 on egts.

03 cclb dually,6.0,arp studs,bpd oil cooler,bpd 6 phase ficm,bpd water pump,bpd all aluminum cac,all aluminum radiator,amsoil bypass oil filter,ipr high flow coolant filter,egr delete,livewire ts tuned by Vivian & tony,php ficm tuner,dc power 300-spx,Detroit trutrac,6" dual side pipes,07 front end,custom front bumper,shaved badges,led button roof lights,08+ mirrors,12 tailgate,13 rear bumper,13 tail lights,dropped I beams,custom rear 4 link w/bags,k5la train horn,24" alcoa's.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
portcity_gt is offline  
The Following 2 Users Say Thank You to portcity_gt For This Useful Post:
JR2 (10-28-2014), kinnisoj (06-02-2014)
post #5 of 88 Old 06-01-2014, 06:20 PM Thread Starter
Compression Ignition Addict


 
madpowerstroke's Avatar
 
Join Date: Aug 2011
Posts: 1,515
Thanks: 2
Thanked 33 Times in 23 Posts
Mentioned: 0 Post(s)
Quoted: 0 Post(s)
Feedback Score: 0 reviews
Quote:
Originally Posted by portcity_gt View Post
I welded the bpd tank kit on my stock cooler and for sure lost 100 on egts.
I can believe that, which is exactly why I want to do the comparison. I know I lost about 100-150 degrees on egt with the banks, and have heard about same with other brands. I also plan on welded BPD tank kit also in the comparison. If you can get away with the welded kit and does same as a Banks for less money then why not.

Now some may say that I'm not measuring flow of air and they would be right, but then some of flow is related to heat. The least of amount of resistance is also measured by heat, but in the end it is the efficiency that I'm after. Some intercooler company's talk about the bar system vs fin system, also some about core thickness. I just think it would be nice to find out what is really happing by measuring it.

2004 F250 Ext.cab fabtech 5.5" lift,and traction bars 35" on 18".2005-2007 grill and LED headlights,58v FICM, Warren dual HPOP system, fuel reg. return system, areo 1000a fuel pump, dual fuel filters, ARP studded heads, CCV reroute, EGR delete, 225/75 Warren injectors, water/meth injection (cooling mist),SCT tuner with customs, banks intercooler. MTW stage 4 turbo, built trans by Andy Warren, 4:10 Detroit lockers.
madpowerstroke is offline  
post #6 of 88 Old 06-02-2014, 09:25 AM
Compression Ignition Addict
 
Diesel996's Avatar
 
Join Date: Mar 2011
Posts: 246
Thanks: 5
Thanked 8 Times in 8 Posts
Mentioned: 0 Post(s)
Quoted: 0 Post(s)
Feedback Score: 0 reviews
This is great as I am in the market for an intercooler. Looking at Banks vs. Spearco/Turbonetics vs. Mishimoto.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Brian

'06 F-250 SD Harley Davidson CCSB (STOLEN)
8" Double Shock Hoop Lift - Pro Comp / Fox
37" Toyyo MT's
175/stock Warren Injectors
MTW Stage II Turbo
WPE Ported Intake Manifold
EGR Cooler Welded
Line-X Extra
and more...
Diesel996 is offline  
post #7 of 88 Old 06-02-2014, 10:34 AM
Premium Member

 
peixinho's Avatar
 
Join Date: Feb 2012
Posts: 3,717
Thanks: 205
Thanked 365 Times in 278 Posts
Mentioned: 60 Post(s)
Quoted: 150 Post(s)
Feedback Score: 2 reviews
Quote:
Originally Posted by portcity_gt View Post
I welded the bpd tank kit on my stock cooler and for sure lost 100 on egts.
I personally have no data at all... but that seems very hard to believe unless something was wrong with your intercooler before. By simply welding on new ends you are basically keeping the same shaped, size, design, and cooling abilities of the stock cooler. The end tanks don't do the cooling... the center section that remains the same is what cools the air. It is hard to imagine any huge gains by changing from plastic to metal... well except being able to hold higher psi

KC Turbos
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Warren Diesel Dealer
My Current Build Thread
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


Current Setup 190/30 and KC 64mm Stage 2 turbo

Last edited by peixinho; 06-02-2014 at 02:49 PM.
peixinho is offline  
post #8 of 88 Old 06-02-2014, 10:50 AM
Serving Our Country!
 
6.0newb!'s Avatar
 
Join Date: Apr 2012
Location: Irvine, California
Posts: 593
Thanks: 6
Thanked 8 Times in 8 Posts
Mentioned: 0 Post(s)
Quoted: 12 Post(s)
Feedback Score: 2 reviews
Very interested in this as well


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
06 f-250 ECSB xlt fx4, MBRP 4" cool duals, AFE stage 2 intake, BPD water pump, BPD egr cooler, stc update, stand pipes, dummy plugs, blue spring, late 04 up pipe, wicked wheel 2, PMM coolant filter, Riff Raff ic boots, t6-5w40, Rotella elc, leveling kit with 350 blocks, Pro Comp pro runner shocks, full Powerstop z36 brakes, PHP ficm tuner, insight cts w/egt, SCT x3 with canned tunes...... for now
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
6.0newb! is offline  
post #9 of 88 Old 06-02-2014, 11:40 AM Thread Starter
Compression Ignition Addict


 
madpowerstroke's Avatar
 
Join Date: Aug 2011
Posts: 1,515
Thanks: 2
Thanked 33 Times in 23 Posts
Mentioned: 0 Post(s)
Quoted: 0 Post(s)
Feedback Score: 0 reviews
Quote:
Originally Posted by peixinho View Post
I personally have no data at all... but that seems very hard to believe unless something was wrong with your intercooler before. By simply welding on new ends you are basically keeping the same shaped, size, desin, and cooling abilities of the stock cooler. The end tanks don't do the cooling... the center section that remains the same is what cools the air. It is hard to imagine any huge gains by changing from plastic to metal... well except being able to hold higher psi
I agree with you, like you said no data at all, so lets get some. Until I gather the data can't say one way or another. The testing will not put a end to the great intercooler debate, but will collect data to show how much of a air temp charge difference there is.

Ok, I will let something out, I plan on collecting the data so I can use it against a air to water intercooler kit that I will putting together. A air to water intercooler are suppose to be more efficient, but not too good for street. So my plan is to test air charge, then build the air to water system and see if temps can be made to stay down. The kit is a bunch of parts gathered of the internet, not a 6.7 system conversion, not that the conversion wouldn't work. The kit that I put together I will share, not interested in sell a kit, just something I will like to try out and if someone else wants to try it great.
madpowerstroke is offline  
post #10 of 88 Old 06-02-2014, 12:30 PM
Compression Ignition Addict
 
04cr450's Avatar
 
Join Date: Jul 2012
Location: bel air, maryland
Posts: 2,121
Thanks: 4
Thanked 48 Times in 39 Posts
Mentioned: 0 Post(s)
Quoted: 0 Post(s)
Feedback Score: 1 reviews
Quote:
Originally Posted by peixinho View Post
I personally have no data at all... but that seems very hard to believe unless something was wrong with your intercooler before. By simply welding on new ends you are basically keeping the same shaped, size, desin, and cooling abilities of the stock cooler. The end tanks don't do the cooling... the center section that remains the same is what cools the air. It is hard to imagine any huge gains by changing from plastic to metal... well except being able to hold higher psi

Agreed, no way you can loose that much temperature from welding on ends- bulletproof has to sell it somehow right? lol To have the most efficient cooling intercooler system, the cooler should have a "plate style" exchanger(s) which the spearco does have hence the higher cost with it. A radiator style(s-channel) exchanger(which the factory cooler has as well as banks and all others) is no where near the efficiency as the plate style exchanger. In for the testing though!

Late 04 f350 lariat.

bpd
marty's regulated return
205/75 injects from holder's
WPE stage 3 ported intake
64.5 borg warner fmw ,compounds in the works now! Comp turbo set up
Warren comp trans
all the typical mods
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


Big thanks to Dale! The man is a true professional
04cr450 is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ford Powerstroke Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome