intercooler
 

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?:c:

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.