DIY Frontmount I/C install project

9

93ty475

Donating Member
Andreas's clever enginuity has inspired me to get off my butt and try this...I am running the core upside down from the way he has it though, to not have to locate my battery to the rear of the truck.....this project is also helping me avoid doing what I really need to be doing (swapping in solid mounts and JS pads)...since I'm doing this by myself at home, It will only cost parts and running around which isn't a whole lot...But if you were to pay someone to dissasemble, cut rad support ect., reassemble, it would cost a crapload of cash....That's where the RPM and McCoy units are a much better deal if you're not comfortable with what's involved here....Their's are much better designed than this setup and you get to keep a/c and much easier to install....so far I've installed the core, and mocked up the 3" aluminized piping from the I/C to TB....the I/C to TB piping consisted of cutting two 3" Jbends exactly in half at the 90 degree point.....no further trimming of the three pieces I used....they fit like a glove....I'm waiting on a few ebay parts that I ordered, needed to finish this....so it'll probably be a week or so more to completion....waiting for a silicone 4" to 3" reducer and a 3" to 2" reducer to hook up the turbo....also one more rubber 90 for the I/C to turbo connection.....also, I set the core up so it can be removed from the front of the truck without messing with the radiator....I'll update more as I go.....hope you guys like it....


pics here
 
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Deanzsyclone

Deanzsyclone

New member
Re: Frontmount I/C install

Re: Frontmount I/C install

Looks sweet so far, I guess your going to be using electric fans? Where did you get the 3" piping from? I have found those silicon connectors are expensive, anybody know where they can be bought reasonably.
Oh and isn't this suppose to be in the Members Project forum?
 
9

93ty475

Donating Member
Re: Frontmount I/C install

Re: Frontmount I/C install

thanks Dan...

Dean, the jbends or ubends can be bought at any real muffler shop....I paid around 20 dollars for each of the three that I bought...I bought two 180's and a 45....used 75% of two 180's so far....Yes, I'm going to install electric fans...I don't trust my new adjustable alternator mod to an engine driven fan...plus, I don't want an engine driven fan under my hood for safety concerns and parasitic lag in our hot temps down here...fan clutch is almost always engaged.. ..I'm not going to use the blue silicon you see pictured....more than likely I'll weld those two joints with a mig....I bought three feet of 50 psi radiator hose for semi trucks for 11 dollars a foot, at a local big rig parts store....and 6, 3" Tbolt clamps for 5 bux each.....the radiator hose is very rigid and best of all, it's black.... :cool:

yea, someone should move this thread as I posted it in the wrong forum....shame on me... :lol:

S2010084.jpg
 
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SeattleSy#1255

SeattleSy#1255

Category 5 Conservative
Re: Frontmount I/C install

Re: Frontmount I/C install

great stuff...nothing like the feeling of doing your own work when possible.
 
0966Sy

0966Sy

Code what?
Re: Frontmount I/C install

Re: Frontmount I/C install

Im probably going to be doing this also. Looks realy good Servando, what is the core thickness? should perform realy well. Dont bother with the Ford fan, get the Ramcharger's you will not be disapointed. You've probably seen the ones on Bruce's Syclone. Get back to work so we can see some pics with it all finished up. Haha just kidding
 
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P

PPI Typhoon

DIY Madman
Re: Frontmount I/C install

Re: Frontmount I/C install

0966Sy said:
Im probably going to be doing this also. Looks realy good Servando, what is the core thickness? should perform realy well. Dont bother with the Ford fan, get the Ramcharger's you will not be disapointed. You've probably seen the ones on Bruce's Syclone. Get back to work so we can see some pics with it all finished up. Haha just kidding
Click to expand...

Yeah, I have to agree. The taurus fan IS nice for the flow, but it's just not the right size to easily fit to a radiator. Maybe with a custom radiator, but for stockers.........it just makes sense to go with the Ramcharger's fan.
 
Divergent Lightning

Divergent Lightning

woah
Re: Frontmount I/C install

Re: Frontmount I/C install

is that a 4 inch thick intercooler? Could you get away with having AC with only a 3" thick intercooler?

Looks like a good install so far. Couldn't you get a regular S truck radiator support to cut up rather than cut up the stocker?
 
Syborg Twin Turbo

Syborg Twin Turbo

Syborg Twin Turbo
Re: Frontmount I/C install

Re: Frontmount I/C install

is that a 4 inch thick intercooler? Could you get away with having AC with only a 3" thick intercooler?
Click to expand...

most likley not - you don't want the AC condensor in front of the intercooler. As the AC condesor create it's own heat. Thus it will heat up the intercooler.

trust me it's tough trying to figure out where to stick everything.
 
Deanzsyclone

Deanzsyclone

New member
Re: Frontmount I/C install

Re: Frontmount I/C install

Divergent Lightning said:
is that a 4 inch thick intercooler? Could you get away with having AC with only a 3" thick intercooler?

Looks like a good install so far. Couldn't you get a regular S truck radiator support to cut up rather than cut up the stocker?
Click to expand...

Hmm I just had the AC removed from my truck (nice and cool here in Ventura all the time) and I forgot that clears more room in the front radiator, I wonder if a 4" thick intercooler core would fit????????????????????????/
 
bezerk

bezerk

New member
Re: Frontmount I/C install

Re: Frontmount I/C install

nice setup!!!
we should have an award for the best looking, DIY frontmounted intercoolers
 
9

93ty475

Donating Member
Re: Frontmount I/C install

Re: Frontmount I/C install

Mine is the 3" thick core...Will's is the 4" thick core....The only difference I would have had with the 4" is the front of the core would protrude 1" further out than mine is in the above picture where you see the nose of the buick...I just made sure my core was mounted flush on the inside where it counts (on the radiator side)....

As far as the fans go, the ramchargers fan on Dan's fan thread looks pretty thick....I hope that doesn't become an issue here....I'm trying to setup this 3" piping as close to the motor as possible for these very reasons....I just don't have everything here at home such as the fan setup for mocking up purposes....

Clint,
This "is" a regular s-series radiator support ;), but you're right, the easiest way for someone to do this is to buy a $95.00 new taiwanese radiator support, get all the hacking done and core mounted, then tear the truck down and swap in the modded support....mine just happened to already be removed in anticipation of my upcoming motor mount swap job....If I wanted to make this nicer, the support could be boxed in with sheet metal where I cut for the inlet/outlets.....I wouldn't try to do this and keep a/c....seems like that would be an extra pain in the butt....
 
R

RedTyFoon

New member
Re: Frontmount I/C install

Re: Frontmount I/C install

Servando for your information i dont see using the ramcharger fans with your piping being a problem. They are 3" thick at the brackets that go across the fans themselves if that makes any sense. Considering your piping runs at the topside of the radiator i think you will be ok here.

Is your 3" core mounted flush up against the radiator? Andreas 4" core sat flush with the front of the core support and it fit perfect without modifying the hood latch bracket which i think makes for the cleanest install. Although yours is great looking you must have moved the 3" core further forward away from the radiator? any reason for this? Good work again i think your pipes look great.

BTW this is Erik not John!
 
9

93ty475

Donating Member
Re: Frontmount I/C install

Re: Frontmount I/C install

RedTyFoon said:
Servando for your information i dont see using the ramcharger fans with your piping being a problem. They are 3" thick at the brackets that go across the fans themselves if that makes any sense. Considering your piping runs at the topside of the radiator i think you will be ok here.

Is your 3" core mounted flush up against the radiator? Andreas 4" core sat flush with the front of the core support and it fit perfect without modifying the hood latch bracket which i think makes for the cleanest install. Although yours is great looking you must have moved the 3" core further forward away from the radiator? any reason for this? Good work again i think your pipes look great.

BTW this is Erik not John!
Click to expand...

Yeah my hood latch bracket was already notched by the previous owner for the atr BS cooler, so I just continued where they left off... I moved the core forward because I'm locating my radiator forward as well in order to gain engine/radiator clearance...I did it on purpose...I gained between 1/2 and 3/4 of an inch...specs on the ramchargers fan say it's 3 5/8" deep....I show to have around four...can't tell if its exactly four as I haven't put a fender back on to hold the radiator support in it's place....I have a back up plan for the pipes just in case the clearance isn't there... ;)
 
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MAITAI1993

MAITAI1993

DON'T MAKE ME SLAP YOU.
Re: Frontmount I/C install

Re: Frontmount I/C install

deanzsyclone said:
Looks sweet so far, I guess your going to be using electric fans? Where did you get the 3" piping from? I have found those silicon connectors are expensive, anybody know where they can be bought reasonably.
Oh and isn't this suppose to be in the Members Project forum?
Click to expand...
You can also get mandral u bends and stright sections out of summit
 
9

93ty475

Donating Member
Re: Frontmount I/C install

Re: Frontmount I/C install

RedTyFoon said:
Is your 3" core mounted flush up against the radiator? Andreas 4" core sat flush with the front of the core support and it fit perfect without modifying the hood latch bracket which i think makes for the cleanest install.
Click to expand...

I'm pretty sure Andreas's core is the 3"....I set mine up to where there is a space between the radiator and the I/C core....also I gained around 5/8" engine to radiator....Doesn't seem like a great idea to have to radiator directly against the I/C core...I want a gap there even if it's only 1/2" or so....I ordered a volvo fan/shroud setup from a guy in houston.....it's a single fan 3000 cfm setup and being a volvo, it's oem quality....the depth is just perfect for my setup....and best of all, it cost only $65.00.....here has a bunch of them right now....The toughest part about this is waiting for all these little parts to come in....but they're all on the way, so thats a start....

the I/C to turbo connection is going to be cake...3" all the way up to the turbo!!....I'll update with photos when my 3" to 2" reducer elbow gets here....
 
Maxtor

Maxtor

New member
Re: Frontmount I/C install

Re: Frontmount I/C install

Thanks for keeping us in the loop on this, Servando. I am going to do a custom front mount as soon as I get caught up with several other projects. I bought a core and piping off Ebay last year. Several places on Ebay sell mandrel bends, I went with a "kit" of 2.5" polished aluminum bends and straight sections from "veccohighperformance". It seems to be very high quality tubing, but it doesn't appear as if they have anything for sale at this time.

Here is another link off Ebay for a kit I was considering:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=7975470648&category=33742

I agree with your comment about trying to keep the IC off the radiator. Also, regarding the difference between 3" and 4" cores, one of the books I read (I think it was maximum boost by Corky Bell??) didn't speak too highly of thicker cores. They stated that a thicker core would actually restrict air flow. I'll try to find where I read that. There is a lot of discussion in there about end tank design as well. The best tank design (according to the book) is similar to the kind that fits under the bumper like the Kenne Bell and RPM. Putting this design in front of the radiator blocks a good share of the surface area of the engine radiator, though. I really think we need to stick with a design that puts the tanks as far off to the side as possible (like your pics above). I did countless calculations putting my nerd engineering degree to work from my thermal classes trying to figure out the optimal surface area/thickness of the core. One big problem that I ran into is that most vendors don't want to give specifications or don't have specifications on their cores.

Anyway, enough rambling. I have put too much thought into building an IC and not enough time into DOING something.

Keep the pics and information coming!
 
9

93ty475

Donating Member
Re: Frontmount I/C install

Re: Frontmount I/C install

hey mark...I'm trying to make this as easy and cheap as possible....Don't buy more pipe than you need....pictured below is all the pipe I bought and I'm going to have some left over...I just cut the jbends down the middle as shown.......3 of the 4 jbend pieces makes up my I/C to TB....one of the longer ones is left over....the 45 is going to connect the I/C to the turbo....I have to clock the turbo outlet towards the passenger fender and I'm using one of these (in black) to connect the 3" pipe to the turbo....

S2010086_001.jpg
 
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