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Thread: My A/W intercooler build

  1. #1
    Sick 660r's Avatar
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    Default My A/W intercooler build

    Reading other builds on YB and the turbo forums helped a lot so I figured I would share. Got most of the stuff frozen boost. Went with their intercooler, heat exchanger and fans. Having a 12x12x7 tank made with 1" NPT ports. Hose is 3/4" silicon heater hose from graingers. The frozen boost intercooler comes with 3/4" ports but the heat exchangers only come with 1/2" ports. Running 3/4" hose with two 1/2" ports makes no sense I drilled and tapped them. Heat exchanger will go under the bed with 3 small fans. Made a shroud for the fans and welded a 1.5" frame around the heat exchanger to fit all the fans.




    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

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    Sick 660r's Avatar
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    The brake needs new blades so some of the bends are a little rough.




    I'm using a heavy duty Bosch pump sold by lingenfelter. They flow well when working against pressure unlike bilge pumps so I don't need to run 1" lines. They also have a low draw and can withstand constant use with fairly high water temps.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  3. #3
    Sick 660r's Avatar
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    Had to make a new upper rad hose to make room for the intercooler. I cut about an inch off the tstat housing and welded a small bead around the top. This allowed me to have the pipe even lower. Made a diy bead roller.



    I'm considering moving the intercooler so that it sits between the fender and the power steering pump so that it's easier to work on the engine. I can't make the mounts yet because the engine at the machine shop has a lower tb/intake setup. The bov goes before the intercooler since there is no point in cooling air that's not going to be used.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  4. #4

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    Looks awsome Joe
    2000 CC
    11.37@122


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    blackknight's Avatar
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    Good work!

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    Sick 660r's Avatar
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    Thanks guys. Hopefully I get the heat exchanger shroud finished and mounted under the bed but I plan on testing that manual brake swap tonight so who know. My original idea was to mount it like this until I realized how big the shroud had to be.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  7. #7
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    Shroud and where I plan to mount it





    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

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    Looks good to me!

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    Bearded Bastard

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    What are you using for a fluid reservoir or is it getting plumbed into the engine cooling system?

    US Army Vet and ASE Certified Automotive Technician

    When life gives you lemons, make orange juice and leave the world wondering how you did it!

  10. #10
    Sick 660r's Avatar
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    7x12x12 tank in the bed. Hasn't been made yet.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  11. #11
    Bearded Bastard

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    Interesting. My bench build uses an air tank from an 18 wheeler bracketed to the frame rail

    US Army Vet and ASE Certified Automotive Technician

    When life gives you lemons, make orange juice and leave the world wondering how you did it!

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    Sick 660r's Avatar
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    It's pretty typical to put a tank in the bed. 7x12x12 sits flush with the wheel tubs and gives me enough room on the top for a -12 150* fitting.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  13. #13


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    - Josh

    2000 Solar Yellow R/T - Cam Only Truck
    1987 Buick Regal T-Type - WE4 and Blackout
    2008 GMC 1500 Quad Cab
    1989 Jeep YJ - Real Jeeps have Square Headlights
    1971 Buick Skylark - LS SWAP THE WORLD

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    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  15. #15
    Sick 660r's Avatar
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    Backing over curbs won't be an option but the sway bar crossmember provides a little protection.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  16. #16

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    Fans going to be on a thermostat or constant on? Whats the amp draw?

    11.09@123

    Pay now or pay when it comes home on a flatbed. Sometimes both. Part of the game.

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    Sick 660r's Avatar
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    Haven't decided yet but I may use IAT's vs water temp. I'll have Megasquirt control them and the pump. Three amps each. I just ditched a vacuum pump which drew 4 amps and I'm trying to find outer ways to reduce the load.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  18. #18

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    Love the set up
    2000 CC
    11.37@122


  19. #19

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    Love this, thinking of a similar setup. Keep it coming!
    -Billy Webster '99 CC R/T DRTC #785


  20. #20
    Sick 660r's Avatar
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    Thanks guys. The ports I drilled and tapped in the heat exchanger ended up being too large and the fittings bottom out before becoming tight. I have two 1" npt bungs that I'll weld in. Hopefully the tank and motor will be finished this week and I'll start fabing the intercooler supports.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

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    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  22. #22
    Sick 660r's Avatar
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    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  23. #23

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    Quote Originally Posted by Sick 660r View Post
    Nice work on the reservoir Joe. Good foresight on the location tucking it in like you did. Next build I Wana do the same or keep it close the the cab along with the battery box. I'm screwed if I want to use the bed for storage of anything with significant weight.
    2000 CC
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    Nice work!

  25. #25
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    that reservoir is purrrrrr-ty!!!!
    i need a tig so i can start playing.

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