Intercooler Mounting

[Alf]

After more than a year of contemplating, the plasma cutter came out to play!
I cut though the radiator support for tube routing, never liked the idea of going up though the wheel housing. Just personal taste. Bracing will be added to the support to maintain it's integrety.
The cooler will hang verticaly, protected by bushbar uprights on either side. They will also help fence in air flow, creating a higher presure area in front of the cooler. There will be no loss of ground clearance,as far as the cooler is concerned. only aproach angle. Since this is my tow rig that never goes of road I'm not worried there.
To further enhance air flow, I'll be ading a spoiler across the bumper below the cooler that will create a low presure area behind the cooler and pull more air though. It will be semi flexible to avoid parking curbs and the like.
I'm welding a cast aluminum 90 to the intake horn, relocate the iat sensor and the boost sensor. The new inlet will face the driver side, without covering the fuel filter. It will also unshroud the pump and PMD for better cooling there.
Routing of the piping on the driver side required relocation of the power steering cooler.
Not sure exactly where yet, but not dangling as the third photo shows.
I'll keep ya posted.

http://gasphoto.smugmug.com/photos/57823338-M.jpg


http://gasphoto.smugmug.com/photos/57823336-M.jpg

http://gasphoto.smugmug.com/photos/57823346-M.jpg

[JoeyD]

Intercoolers are always a good thing for the 6.5
Are you concerned about the bumper brackets? I have to say they will fold up on even a minor hit.

[Alf]

Yes you are right, now the only thing they are good for is to hold the bumper in place while the pushbar gets built. The new pushbar uprights will more than replace the bumper suports.

[stingthieves]

So please do not take this question wrong I like your design; but why didn't you simply move up a few inches and place your flanges just above the frame rails?

[DmaxMaverick]

Not bad going through the bumper support. Just weld in a section of steel pipe. It'll probably be more rigid than before you started. Just use a pipe with inside dia. about 1/2" larger than your I/C tubing, and fill it with expanding foam once completed. You'll maintain the integrity of the bumper mount (such as it was), and prevent any chafing the may occur with your current plan.

Good luck with the project!

[Alf]

Stingtheives,,
If It sits any higher it would block airflow to the radiator, and interfear with the grill when it gets re installed. My thinking is that the bumper will cover the top of the cooler for a more finished look.

DMax,,
When I get it done the cooler will sit on a base just like the radiator does. Current pictures are just a step in the thought/design process.

Thanks for the encouragement!!

Alf