Fantastic I've been waiting to here how this came out. Did you make the custom throttle inlet? Can you tell us more about it. I don't know how or if I can put an intercooler rad behind my winch. But this I feel is a must, so I will half to figure it out. A complete parts list would be a big help to me, ordering from PNG. Thanks for all your hard work, I've benefited greatly.
OK, I finally found some time to get links for the parts I bought. I did not use all of these sellers, but these are the same parts that I used. Anyone buying these parts will have to find the best seller/shipping options for their location/application.
Intercooler:
http://www.ebay.com/itm/CXRacing-Un...Parts_Accessories&hash=item3a7b7ff60d&vxp=mtr
Radiator:
http://www.ebay.com/itm/UNIVERSAL-A...Parts_Accessories&hash=item2ec55955eb&vxp=mtr
Pump:
http://www.ebay.com/itm/Bosch-Cobra...r_Truck_Parts_Accessories&hash=item27c6a2541e
Custom Throttle Inlet:
I will post drawings of this here so that people can fabricate their own. I've also asked the guy who made mine if he would want to make more for other people. In that case folks could buy them instead of make them if they wanted.
Pipe/Hose/Brackets/Electrical:
There is no single 'kit' for these parts. Look carefully at my pictures to determine what you need, and buy the parts individually. Basically all my aluminum piping is 2". I used a straight piece, a 180degree bend (cut in half, rotated, re-welded), and a 90degree bend. All silicone couplers are 2", except the reduction couplers at the intercooler that go from 2" to 2.5". Also, a 90degree silicone coupler is used at the throttle inlet. I used 2" and 2.5" T-bolt hose clamps.
I used 5/8" heater hose for the coolant, but 3/4" hose would have been better. I used a 90 degree NPT 1/2" adapter at one end of the intercooler. I bought a standard heater hose coolant bleed/fill access point to fill the system. My system is closed with no expansion tank or relief valve. I've only seen the water temp get up to 40C, so I don't think it is necessary. I used regular hose clamps.
I used a large step drill to drill holes for the hose in the front of the truck.
I used miscellaneous bits of rolled steel flat bar and aluminum flat bar and L channel to make my brackets. I also used some stainless sheet metal and rubber isolators. You don't have to do it how I did, just do what ever works for you best. Making the brackets is the hardest part of the whole install though.
I bought a standard 12V 30Amp relay, and a fuse holder. I wired the relay up to the Power Accessory box under the hood.
The only problem with my setup is the mounting location of the pump. It is too high in the system, and mounted at a bad angle. It tends to capture any air in the system, and then the pump cavitates. Once I got the air out of the system, it was fine. But I'd highly recommend mounting the pump next to the radiator low down at the front of the vehicle to avoid this problem. In fact I'll probably move my pump eventually.
Hopefully that helps.
All things considered, your are probably still doing relatively well with your mileage. That said I will be interested to see how an intercooler will affect your economy.
Still love the truck, can't wait to get a bit more power, going up hill can be little painful and shameful sometimes hahaha
