My 1994 6.5 intercooler setup

[Suburbank2500]

Hi

As i promised, here is some pictures from my custom Intercooler project.

I got me a used, dented hood. Startet to straighten out the hood.
Cutted out the piece from the donor hood(Subaru Forester Diesel).
After carefully measurments i cutted the hole in the hood.
The donor piece matched the curves on the GM hood very good.
Then i started to test fit the Cooler in the engine bay, to get the correct height. and make romm for selings, and movements of the engine. When all this fidling was done i finished the hood, primed it with epoxy primer, and filler.
Painted the cooler im matching color. Some pics from the paint shop.
Then i made some covers to protect the electronic, and the fuel pump, i figured that there could be some dirt, and water "flying" in.
I made the cover in a way so it would not stop the airflow to cool the pump, and FSD cooler. The piec on the right in the image side is the one covering the pump.
Next pictures shows the covers installed.
Then it is pictures of the brackets for the cooler.
Two pics of the intake, and the way i cut it to make it fit.
As you can see i turned the intake 180 degrees. This way i have room for the electric pull fan.( from a Toyota)
It makes it alittle bbit troblesome tho change the fuelfilter, but i figured thet will be ok.
Then we have som pictures of the routing of the "plumbing", and the finished hood all installed.

Børge

 

[NVW]

Looks really nice! Good job.:thumbsup:

 

[Suburbank2500]

I bought the hood decals from Ebay. 6.5 DIESEL TURBO GMC CHEVY HOOD DECALS STICKERS C/K (380199124604)


Member id prop_kulture

Børge

 

[Suburbank2500]

Added a cover to protect the Generator from direct moisture.

Børge

 

[Suburbank2500]

i forgot to mention how if installed the scoop to the hood.
The sccop piece was attached with bodywork glue used instead of welding, and reinforced in the seams with 6mm stinless steel rod glued on the inside of the hood.

Børge

 

[Burning oil]

So the Forester scoop if a composit?
Look like top notch work. What do you do for a living? must be in fabrication of some sort?

 

[Suburbank2500]

Looks really nice! Good job.:thumbsup:

Thanks NVW.

 

[Suburbank2500]

So the Forester scoop if a composit?
Look like top notch work. What do you do for a living? must be in fabrication of some sort?

Hi Burning Oil, and thanks.

The donor piece is of metal.(from a damaged hood.)
The insert piece is of Abs (original part).
I don work with fabrication, just love to make things.
Went high scool in Electro.
Thet made me think of another project on the truck i did some years ago.
The carputer
i will post some Photos of this to in "interior components"

Børge

 

[Suburbank2500]

Link to the carputer pictures

Børge
http://www.thetruckstop.us/forum/showthread.php?35201-My-Carputer

 

[racedaymechanic]

looks good, but you would get more air with the scoop turned around facing the windshield

 

[Burning oil]

He has the puller fan so air is not an issue.

I like the structual adhesives available for body work also. Much easier to use, rust protection in the joint, no warpage from heat of welding....I use it when I can also.

 

[countryboy69]

First let me say....VERY NICE!

You have given me some ideas and I will run with them! I had an air to air brought to me a few days ago that would be perfect for this! Even bought it for $0.56 a pound!

I was planning a cowl hood anyway but now instead of giving 400+ for one I will be building my own!

Am I right in assuming that doing it this way cuts down on pipe length over a front mount and saves from some of the lag?

Great job and thanks for sharing it with us.

 

[buddy]

A tall enough scoop can definately pull in more air than a cowl setup. It just has to be tall enough to be in the airstream going over the hood, which should only be about 2" above the hood. There in lies the problem with most of the fake scoops on cars these days, they are fake because they wouldnt work being so short.

 

[Suburbank2500]

First let me say....VERY NICE!

You have given me some ideas and I will run with them! I had an air to air brought to me a few days ago that would be perfect for this! Even bought it for $0.56 a pound!

I was planning a cowl hood anyway but now instead of giving 400+ for one I will be building my own!

Am I right in assuming that doing it this way cuts down on pipe length over a front mount and saves from some of the lag?

Great job and thanks for sharing it with us.

Hi countryboy69, and thanks for nice words.

What kind of cooler do you have available.
I guess you can save 1-2 mtrs. of plumbing when fitted on top.

Depending on the way you are designing the hood, there is not a lot of clearanse. between the hood and cooler.
i think my cooler is about 45mm thick. You also have to make room for rubber sealing between the cooler and the hood.
And clearance for the engine to "shake it".

Børge

 

[ak diesel driver]

I've thought about something similar but doing a "shaker style"

 

[racedaymechanic]

A tall enough scoop can definately pull in more air than a cowl setup. It just has to be tall enough to be in the airstream going over the hood, which should only be about 2" above the hood. There in lies the problem with most of the fake scoops on cars these days, they are fake because they wouldnt work being so short.

That was my point about turning the scoop around, Ive been to the windtunnel many times and the air will go right over a low scoop and actually pull a vacuum there
bat at the base of the windshield there is positive pressure

 

[Burning oil]

I've thought about something similar but doing a "shaker style"

Thats a cool idea (no pun), could be mean looking to if done right.

 

[Suburbank2500]

I've thought about something similar but doing a "shaker style"

Hi Ak Diesel driver

That would be cool, not many 6.5 with a shaker hood i guess.

Børge

 

[Suburbank2500]

A tall enough scoop can definately pull in more air than a cowl setup. It just has to be tall enough to be in the airstream going over the hood, which should only be about 2" above the hood. There in lies the problem with most of the fake scoops on cars these days, they are fake because they wouldnt work being so short.

Hi buddy

I totally agree, i tried the suction effect with a t-shirt. I held it in fron of the intake and dropped it, it got sucked right in.

Børge

 

[Burning oil]

Hi buddy

I totally agree, i tried the suction effect with a t-shirt. I held it in fron of the intake and dropped it, it got sucked right in.

Børge

They are refering to the vehicle at interstate speeds/55-70MPH. Personaly I think you'll get plenty of air with a suction fan under the IC.