Looking good. Alot of little things can get frustrating. Glad to see you getting that in there. You may want to save your Bank$ stuff and throw it on EBAY. I'd bet it would bring more than what you'll have in all this.
I am done. Now I want to get 3 inch cooler tubes to finish it off. My HTT stage 4 will be here this week. For now I have pieced together some pipes with some furnco's so I can atleast run the thing. Basically everything between the fan to bumper needed to be cut or moved or replummed. I have everything installed but the A/C condensor. I need a new one so there is no sense to install a cracked unit.
I had to cut the trim under the grill
I had to shorten the secondary hood latch so it would not hit cooler
I hit like 25 pounds and blew a furnco.. I hodgepodged some pipes to get it to run. I have a restrictive 2 inch elbow on the turbo, I think it necks down to like 1 3/4 in the bend, then to 3 inch. After the intercooler it reduces back to 2.5 inch into the original banks tube.. Its a plummers nightmare but at least I can drive it till my htt comes and then gonna get 3 inch cooler tubes and do it up right. I think it will ( once piped up right ) be a nice unit. It was a pain but it is a much bigger unit and of course has 3 inch pipes. I think I got 25 to 30 hours in it including going to get parts. Even with getting cooler tubes I should have about 500 bucks in it. Its better then buying a new one for 700 then having to plumb it for a nother couple hundred. I did alot more cutting then I wanted. I think on a factory intercooled truck there is less cutting and fab work involved.
Im located in Maine. Price breakdown... I paid $150 for the intercooler. They wanted 200 but talked them down. $15 bucks in mis metal peices for core support, I bought a ton of bolts and nuts, threaded rod for 20 to 30 bucks.( only used couple of bucks worth ) Put the rest in the bolt bucket. Got 30 bucks in temp exaust pipes for cooler pipes. I bought some furncos at 8 bucks apiece.( temporary fix ). 2 cans spray paint to paint everything I chopped up. I guess thats about it. Looks like I will have 250 bucks in cooler pipes and boots. I could have saved 50 or 60 bucks if I wanted to wait and do final pipes before driving truck again. Who wants to wait? I couldn't.
Thanks. I guess it ads up quick. I got the same IC for $150 also and then the intake manifold off an '02 or so for like $20. I've been sitting that stuff for a while and will install it when I do my motor swap into the Ford.
I never thought the boots and tubing would cost that much but I guess they do.
Are you doing 3" aluminum tubing for the cooler pipes and making your own using rubber or silcone bends - or are you buying a prebent set somewhere?
I'm going to look around for some 3" aluminum tube and a place with a mandrel bender to do mine.
Any muffler shop should be able to bend 3", but most muffler places don't have a mandrel bender so the tubing dia. decreases in the bend - which I don't like.
Look under any car or truck around to see what I mean by this.
If you get aluminum tubing anybody can polish it after you have it bent - heck I might even do mine.
Just don't take an already polished piece to be bent - you won't like how it looks after...
Oh - you can make the intake pipes out of steel as well and it will be cheaper. You don't get the cool polished look, but you can paint them any color you want. I just like aluminum because it dissipates the heat faster.
A forum community dedicated to Dodge Cummins Diesel truck owners and enthusiasts. Come join the discussion about reviews, drivetrain swaps, turbos, modifications, classifieds, builds, troubleshooting, maintenance, and more!