Has anyone ever though about putting and intercooler on their 6.5? What would be the pros and cons putting one on the truck? Or would it even be worth it?

 

I have considered it heavily.

Pros:
lower IAT
which creates a denser air charge
which makes more power

lower EGT, as long as you don't turn up your fuel

Cons:
turbo lag, depending on piping length
pressure drop, typically is 2-3psi

both of which depend on pipe size.

 

Well I'm heavily considering it myself but I'm not paying damn near $1000 for an intercooler kit when I can get a universal kit for about $120 and modify it to work

 

Waste of money..unless you upgrade turbo

 

Lots of universal kits on ebay-you need 1 for up to 500 hp.
Check PM's,I sent a link of examples.

Penninsular diesel makes a great upper intake for connecting the intercooler-some cut and modify the original or turn and mount it 180 degrees from stock to make connecting easier.

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The stock turbo's really heat the charge and benefit the most from water injection or aftercooling/intercooling.

An upgraded turbo actually reduces the need for intercooling unless you strive for much higher boost than stock.

 

I guess this means you got your battery situation taken care of?

 

Yea mase I broke down and bought 2 nre batteries for it. Its running like a dream now, no hard starting or anything

 

Once you start crossing 8-10 psi you are in to the range where cooling the intake charge has significant benefits. That a "rule of thumb" range.

Below that, there are some benefits but not as pronounced. Generally, the added complexity and cost are seen as not a good return for the effort.