hey guys, i have a powerdyne charger right now on the truck. i have BBK underdrive pulleys, dual electrics, new fmu, inline fuel pump, plugs etc etc. i need a dang intercooler. out here in the desert it gets kinda hot during the summer and experiencing heat lag bad.

I have checked ALOT of places, and can't seem to find a direct bolt up. so here's what i need: suggestions on an intercooler. preferably pictures. i can do fab work so that's not a problem.

details on the truck:

2002 Ford F-150 5.4
it's got the stock 3.55's, but those are coming out next month. what ya'll think would be a good replacement? i have 20"s on it, but i also don't want to lose much on the top end.

 

According to a quick search, as you know, powerdyne does not make an intercooler for their applications.

A quick search of ebay yielded 15 hits on "water to air intercooler" All of these appear to be designed for the turbo market but if you can weld aluminum you could cut off the inlet/outlet tubes and fab up connector to put this unit inline.

 

yeah, i was just trying to see what people on here have done and tried, and HOPEFULLY can get some pics...

 

Check my gallery. I did an air/air on my Powerdyne and I can offer some short cuts if you like.

 

I have the powerdyne as well, and ran into the same dilema. It ain't purty, but this worked



All used parts off ebay.....You can see the intake and return for the coolant between the intake pipes. The heat exchanger is down under in the lower grill opening, the coolant tank is behind the right headlamp. Works well

 

I am running a powerdyne with a 2.5 pulley and use a Vortech 5.0 Mustang air to water after cooler with Lightning pump, heat exchanger, Tank and hoses I did a slight modification to the inlet side to make a neater installation, but everything fit well. Intake air charge temperature stays within 10 degrees of ambient, the highest temperature that i see after a major pull is 108 to 110 degrees this is down from nearly 200 degrees before the after cooler. This is a very easy unit to install and works very well for me. The boost loss is less than 1/2 lb.

 

ok, here's another question: where do you get bent 3" piping? no one here in abq can bend 3" pipe...

i like the vortec setup alot.

 

Try an ebay search for "intercooler", for pipe and coolers.

 

I ordered a kit off ebay, was like $127 for a huge kit with next day air shipping. Came with pipes, clamps, and connectors. I would however, recommend better connectors as the cheap thin blue ones will expand and blow off under the heavier boost conditions

 

Since you are fabbing it up yourself, you could go with the style that ATI usees for the Procharger. It's a common 2- or 3-core air-to-air, so you can get them generically. It was really easy to mount.

No coolant lines to worry about since its air-to-air, and at least for my bumper style, it gets plenty of cool airflow.

My inlet air temps, measured just before the TB, are consistently about 15 degrees or so above ambient, and I peak at 10.5 psi.

You can see it thru the opening on my front bumper: