I have a 1997 Expedition 5.4l with the Ford Motorsport kit (which I hear is just like a powerdyne kit) and will be adding on an air to air intercooler setup like procharger's. Now I'm wondering what size intercooler piping they use (o.d.) and what the size and spec is of the intercooler is?? Just need to know as far as thickness, length, height, and inlet/outlet sizes??
I heard that they're 2 row intercoolers?

 

Welcome to the forums.
I had a DIY air intercooled Powerdyne set up. If you click on the camera next to my info you will be able to see my gallery which still has a few Powerdyne pics.
Here is the intercooler I used with some modification.:http://cgi.ebay.com/ebaymotors/FMIC-...QQcmdZViewItem
Three inch aluminum pipe and fittings can be found on ebay.
Here is a thread I started when the project began.https://www.f150online.com/forums/sh...ight=Powerdyne
Good luck.

 

Hi Onelowf,

thanks for the links and further info??? Now just to clarify, you used 3" intercooler piping?? The same size as the intake piping you have?? I viewed your pics, and my biggest concern is that if it is the 3" piping than there may be too much pressure drop for the little powerdyne?

Also, how does the powerdyne supercharger itself compare to your new paxton or other centrifugals such as the one that procharger uses?

 

Yes, 3" piping with a 4" IC core. I believe the Procharger is 2.5" piping. I have heard the same pressure drop question from other members here. You could easily try 2.5", as the part and reducers are easy to come by. The mounting and packaging of the intercooler itself is the biggest challenge.
Compared to other users with water/air intercooling, I was losing at least one more PSI of boost, probably one and a half PSI at WOT. I have looked at the whole process as an fun experiment, for which the only restraint was engine safety.
I think the Powerdyne is rated at 750 cfm, the SQ Vortech 1,000, the Pro 1,200, and Pax N2k 1,700. Remember that our trucks with the NPI heads will show more boost than the 99' later trucks with PI heads, and that boost is only a measure of resistance.

 

wow, thanks for your help! I really didn't know that the powerdyne flowed so little???

Did you notice a huge difference when you put the paxton on?? I mean the boost was probably the same but do you feel you gained considerable power?

I also noticed that you put a fan on the intercooler, did your intake temps rise that much that there was the need??

 

The Paxton seems to make a lot more power than the Powerdyne. But don't take the cfm numbers I posted as absolute fact. I have looked around and this is what I have come up with.
I believe the 12" fan on the intercooler makes a big difference, as the intercooler is behind the bumper with little direct air flow. Sc compression creates heat.
Here's a primer on the Powerdyne:https://www.f150online.com/forums/sh...ight=Powerdyne

 

A second option that you may want to consider is using a Vortech air to water after-cooler. This set-up is a little more expensive to install but is very easy to install and boost loss is less than .5# and efficiency is very high. These come up on eBay all the time. I used a Mustang 5.0 after-cooler and WLF used a Mustang 4.6 unit. We both used a lightning lower heat exchanger that bolts right in behind the bumper and the lightning water pump. these units will lower discharge temperature to with in 10 degrees of ambient. on a long run my temps are lower than cruising temperatures without the after-cooler. It is much easier to route 3/4 inch heater hose than 3 inch tubing.