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post #1 of 11 Old 01-31-2013, 03:18 AM Thread Starter
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97 Intercooler

So im slowly but surely working my way to build the truck up. I want an intercooler but the 1000 dollar price tag has me a bit concerned for my savings account! I have heard of DIY intercoolers. How do you build one? Where do I get parts? And total bill at the end of the build?
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post #2 of 11 Old 01-31-2013, 04:40 AM
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the cost depends on how much you can get a superduty intercooler for and if you can fab the pipes yourself. heres a link i followed when i built mine the only difference is i used an all aluminum ic from a 7.3 superduty not the plaqstic ended 6.0 one
6.0L intercooler install in '92-'96 body

95 f250 eclb 4x4 under construction
96 f250 eclb 4x4 rosewood stage 1 injectors, bully dog 6 position chip, 6637 air filter, idm mod
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post #3 of 11 Old 01-31-2013, 08:28 AM
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Total cost on mine was $530 I used an all aluminum setup from a E99 and custom pipes, a good muffler shop can also make pipes

Elmo/Shane

96 F350 4x4
Everything.
And its expensive.

471,000 Miles


"100% worked for, 100% paid for"
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post #4 of 11 Old 01-31-2013, 08:32 AM
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Elmo, what is the diameter of your pipes?

+ Matt - Star Tiger +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, test pipes, intercooler
-Irate: T-4 kit, IC pipes, 3" Replacement Plenums, BASB Turbo
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, SRP1.1
-twin on-board air w/ 10 gal. tank

Re-pinning '97 Cali PCM to Federal
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post #5 of 11 Old 01-31-2013, 08:44 AM
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3"

.

Elmo/Shane

96 F350 4x4
Everything.
And its expensive.

471,000 Miles


"100% worked for, 100% paid for"
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post #6 of 11 Old 01-31-2013, 08:49 AM
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Having trouble finding a shop near me that 1 has 3" pipes and 2 has the ability to do clean bends.


.....for a friend.

+ Matt - Star Tiger +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, test pipes, intercooler
-Irate: T-4 kit, IC pipes, 3" Replacement Plenums, BASB Turbo
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, SRP1.1
-twin on-board air w/ 10 gal. tank

Re-pinning '97 Cali PCM to Federal
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post #7 of 11 Old 01-31-2013, 08:54 AM
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They are actually gentle beds when you look at them. Maybe I will invest in a pipe bender and cash in hahahaha

Elmo/Shane

96 F350 4x4
Everything.
And its expensive.

471,000 Miles


"100% worked for, 100% paid for"
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post #8 of 11 Old 01-31-2013, 08:55 AM
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My Banks tube have near 90* bends but the whole thing is Mandrel.

+ Matt - Star Tiger +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, test pipes, intercooler
-Irate: T-4 kit, IC pipes, 3" Replacement Plenums, BASB Turbo
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, SRP1.1
-twin on-board air w/ 10 gal. tank

Re-pinning '97 Cali PCM to Federal
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post #9 of 11 Old 01-31-2013, 08:58 AM
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Actually, it would be cheaper to buy some mandrel 90's and a 45 and weld them up.
2 90's and a straight for the pass side, 1 90, straight and 45 for the driver, I wouldnt think it would be that expensive to do, then paint them the color of choice

Elmo/Shane

96 F350 4x4
Everything.
And its expensive.

471,000 Miles


"100% worked for, 100% paid for"
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post #10 of 11 Old 02-01-2013, 05:06 PM Thread Starter
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Quote:
Originally Posted by Fordman247365 View Post
Total cost on mine was $530 I used an all aluminum setup from a E99 and custom pipes, a good muffler shop can also make pipes
An intercooler off a 250 or 350 wouldnt matter i guess. my brother is a welder and could get the piping for me, you think it would be less of a head ache to buy pre bends?
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