okay guys, i got my hands on a intercooler out of a 07 5.9 cummins, and i was wanting to know how well of an upgrade it would be? i havnt got the measurments yet, but it has to be better that the stocker, right?

 

its got to be a good upgrade. but have you seen the size of those things? good luck making it fit if it does fit i want some pics

 

I've heard of it being done, requires trimming () of the frame rails a bit. On the other hand, custom IC's are well over 1000 bucks...

 

You need to trim it quite more then a bit...

And a custom I/C can be had cheaper then that. David should chime in soon enough with his set-up.

 

aw come on guys, no one have pics or anything of that nature that would either encourage me or stray me from this idea??

 

Here you are. 3rd Gen intercooler?? - Dodge Cummins Diesel Forum

 

I dunno Tommy, A custom, made to spec IC from Joe Hellman was approx $1300. That IS still a lot less than most aftermarket "kits" for the later trucks though.





Here's the Hellman unit (left) next to a Banks early 1st gen IC (the Banks core is the same size as our stock/OEM unit).





I had Joe build it with 3" plumbing. He uses 3/16" plate aluminum for the end tanks and guarantees the unit to 100psig.





Proper dimensioning allows the new IC to fit dead against the radiator support and just barely accommodate the AC condenser coil.





And then still have something of a custom transmission fluid cooler fit up top.





Certainly, a custom built unit allows one to run the charge-air plumbing where YOU want it.





As large as the new IC is with the 1/2" core tubes, a set of HT3B~S300 62/14 twins blowing full song fueled by some Shiede 6x.016" EDMs presents with only 3psig of pressure drop across the IC and it's associated 3" plumbing.

 

okay well i decided that i do not want to cut my frame, bc i have a 170lb custom made front end replacement, so whats the best bang for the buck without having to cut the frame?
and btw, that custom made ic is freaking wicked!!!!!!!!!!!!

 

Though I have no 1st-hand experience with it, it seems like that IC out of a Ferd Powerstroke works very well and fits with minimal trimming.

There are those with plastic end-tanks and those with metal end-tanks, . . . . go with the latter.

Do a forum search here in these fine forums as well as the others for the Powerstroke IC in the 1st gen sections. Plenty of folks have done the install and a good number have posted How-To's with pics.

 

Nadir Point has a great write up on here on the PS intercooler.

https://www.dieselbombers.com/5-9l-r...tercooler.html

And David I dot know why but for some reason I thought you had about half that cost into your intercooler...