intercooler
 

i want to plum in an intercooler on my 95 powerstroke. so what all do i need and what is the best way to do it.

Your gonna need the IC, I would use one with metal end tanks from a SD 7.3

And for piping I would order the kit from banks, their kit installs really well or you could piece it together using an early 99 spider and making your own pipes

If you can weld you can make your own pipes for about $40 from parts at a wrecking yard...

Then a Early 99 Y pipe.

I have some pictures I have to dig up...

I put one on my truck. I went to a Ford dealer I'm in good with and got an intercooler for a 6.0. I'm told it flows better due to it being a taper core. I've had no issues with the plastic cores on it and I can get up to 40 p.s.i. Not only that it was a lot cheaper. You'll have to push your AC condenser back some. Make some mounts on your frame and cut some holes for your inlet and outlet thru your core support. I ran the factory Super Duty intercooler tubes. I had to cut and lengthen them with some boots in the middle. A 99.5 intake assy. won't fit on that engine. You can get a intake for a 99 Powerstroke. The 99 doesn't have a the air heater on it. They may hassle you, but it does exist. You can use your original boots on the intake, but you'll have take down some of the aluminum on your intake assy. to get it to fit. Once you get the parts, it's gravy. Good luck.

hey thanks guys that is great info. ya i heard that the 6.0 is the one to go with. so now im going to buy every thing and get her put in.

6.0, 7.3... There both more or less the same. I saw less then a 50* differance when I swaped in a 6.0 IC.

Yes, it must be a early 99 Y pipe, but they are avalable at wrecking yards and directly from Ford.

or you could update to late 99 turbo setup