Alright heres the deal im in the process of putting a 92 ve pump ctd in my reg cab 96 f350 and i heard the 99 to 03 ps intercooler was a good idea to put in so i did and now i have not a clue how to make the intercooler tubes. I was thinking get the powerstroke boots that make it go from 3.25 to 3 inch and then get 3 inch tubing get it mandrel bent and then weld 2.75 inch to 3 inch exhaust adapters on the end to make it go into the cummins. Problem is that adapter is aparently an unheard of and that leaves me completey screwed on ideas for what to do. I have had more freaking problems with this conversion than anyone could ever shake a stick at. Please gimme some input so I dont just burn the darn thing to the ground and say screw it.

 

please help

 

OK so what sizes are all four of your fixed coupling points and what size tube do you want to run? If all you need is a couple 3.25-3" and 2.75-3" adapter/couplers and some 3" tube E-bay can be your friend. As far as getting the tube and correct bends, make a layout with some heavy wire that'll keep the shape you bend it in. use the wire as a guide to see is you can use a continuous piece or if you'll have to do it in multiple pieces. Figure out you're angles and then if you want bent pipe, couplers, or a combo of both. It's like building custom radiator hoses or odd-ball exhaust.

2.75-3" coupler

3.25-3" coupler

 

do you really need the ic, if not then just find and non intercooled turbo and or just the compressor housing and switch your intake horn if you can and there you go, besides my 90 non ic ran alot harder than my 92 but the egts were a little harder to control.

 

I was able to use the stock tubes off a 04 6.0 powerstroke, the pass. side is made with a piece of straight pipe with one of the bends welded and a 90degree silicone tube to hook to the turbo,,on the drivers side I used the whole drivers side piec from the PS drivers side, just had to cut it and weld in a 3" piec to make it a little longer, I also used the PS inlet elbow, just made an adapter in place of the intake heater. note these tubes are off of an 03 or early 04 PS, the later ones are plastic on the drivers side.

 

Thanks for the replies I got a 5 ft stick of 3 inch tubing, got some psd intercooler boots that go 3.25 to 3 inch and I found a shop in town that can make me a 2.75 to 3 inch adapter. I asked napa if they had a few 90* bends for 3 inch exhaust and they did however some how 3 short 90's and a 45 ended up being over 100 dollars. I told them to get lost sohopefully just manderel bending the tube will work. I will try your wire trick. Hopefully that will work out.