OBS 6.0 intercooler, banks pipes, NO CUTTING
Couldn't find a thread with banks pipes and a 6.0 intercooler that didn't require cutting the pipes. Finally got it all fabbed up. I did all of the prep work that you can find on numerous other forums but i thought i'd show you how it can fit without cutting those brand new banks pipes.
Had to use some different sized hoses to get it in and she was tight but i got it to work.
Made the lower "brackets" out of 3 pieces of 1 inch strap. Cut them to length and welded them together before welding them to the frame. (be gentle on the crappy weld job. just moved into new house and harbor freight stick welder is all i had...) They clear the frame by about an 1/8th of an inch but they don't rub.
Upper mounts are the same 1 inch strap. Secured them to body with self tapping screws. Secured the ic to the mounts with 3/8" bolts, shock absorber bushing from the autozone help aisle and rubber grommets. With the upper and lower mounts she is solid.
Banks kit came with a bung welded in for boost gauge. No gauge yet so i put in a 3/8 inch plug with teflon if i remember correctly. Plug may have been different size...
The hood release didn't require any modifications and the trans cooler can be mounted above the ic like the pic i posted. I went ahead and bought a trans cooler from a 6.0 as well so that well be going on before final assembly. Probably behind the bumper as that's the only place it's going to fit i think.
I did have to do some trimming to the headlight mounting panel (or whatever its called) to clear the ic but it was superficial. Going to install a billet grill after black powdercoating as i am taking all of the chrome off of the truck.
Here are some pics. Hope this helps anyone trying to do something like this. ( WARNING: you will curse, you will ding your hands, and you will throw tools. but it's all worth it in the end) Make sure you stock up on a good supply on sawzall metal blades as you will be bending more than your fair share clearing the front body panel so the pipes will fit.
Special shout out to my old man for lending me the welder and for buying me a compressor 2 days after i finished the build for xmas. Timing is everything... LOVE U POPS
1995 PSD, AFE BAF Intake, AFE TBE, manual hubs, 6.0 IC w/ Banks pipes, 6.0 Trans Cooler w/ ext therm, HPX, Bean's Electric Fuel, TS 6 Pos./PHP Tunes, HYDROBOOST Brakes, Built Trans/Billet Conv, RR billet wheel, 360 deg bearing, RR bellowed UP's, EBPV Delete, RR banjo bolts, Glowshift gauges, 38 gal tank w/ sump