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Old 01-28-2019, 06:57 AM   #1
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Project: intercooler to 7.3

I'd been saving up parts for a couple years, it's finally time to do this!


My E350 came with a 7.3 Diesel, non-intercooled, but I've always wanted to increase the efficiency of the turbocharger system, lower the intake air temperatures, by adding one, like Ford did on the '98 and later 7.3 trucks. I also have this heat exchanger that would make a perfect extra capacity transmission cooler. The Ford cooler needs to be relocated anyway, I may as well fit and plumb the larger one.



There's a few things that I needed to get started:
Ford intake spider from 1998-early 1999
Intercooler that would fit behind the Econoline grill
Intercooler piping and couplers (custom made)
Transmission cooler










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Old 01-28-2019, 07:01 AM   #2
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Fitting the intercooler and transmission cooler, making brackets... I'm rubber mounting the aftermarket intercooler (like Ford does with theirs) as to not crack welds and joints during use, using grommets from the auto parts store, originally intended for valve cover mounted EGR valves.








The intercooler was a Craigslist find, intended for a Honda B18 street/drag racer. The transmission cooler was a take off from an MRI machine, being retrofitted to a larger one I think. Pictures don't do it justice, this thing is Aircraft quality and a work of art.


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Old 01-28-2019, 07:20 AM   #3
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Nice project! I look forward to your feedback after you get it back on the road.
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Old 01-28-2019, 08:46 AM   #4
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Pretty cool project! I've wanted to do this for a while but it seems too daunting for some reason.
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Old 01-28-2019, 08:55 AM   #5
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So, did this all start due to that fuel leak problem?


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Old 01-28-2019, 10:34 AM   #6
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Quote:
Originally Posted by BroncoHauler View Post
So, did this all start due to that fuel leak problem?


Herb

NO!




Ok, maybe


Come on Herb, you how these things go

"as long as I'm in there, I may as well..."


I had thought about doing this for several years, after a racing buddy of mine told me about intercooling his 1997 OBS truck "It's easy" he said "Just pick up an early '99 spider, an intercooler, and fab up some tubes. Ain't no thang!" he convinced me.



I've been collecting parts for the last couple years, won the oil cooler in a raffle last year, stumbled across a $100 spider a couple months ago. After I stripped the engine valley chasing fuel and oil leaks, I figured it was a good time to quite putting it off and just do it "as long as I'm in there..." LOL!
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Old 01-28-2019, 10:52 AM   #7
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Dealing with the hood latch

The hood latch has always been a concern, in the factory configuration, it's in the way of any intercooler.










Here's the solution I came up with:





It clears the factory grill parts, fits between the hood gap and grill shelf



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Old 01-28-2019, 10:55 AM   #8
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Monster transmission cooler

Mounting the trans cooler.





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Old 01-28-2019, 03:17 PM   #9
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TomsBeast, I'm just on the sidelines as a spectator on this thread because its so interesting, but wanted to compliment your ambition. I'm always impressed by the confidence of members such as yourself to tackle unique projects that aren't mere bolt-on applications...makes the reading here fun!
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Old 01-28-2019, 07:29 PM   #10
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Quote:
Originally Posted by Twoxentrix View Post
TomsBeast, I'm just on the sidelines as a spectator on this thread because its so interesting, but wanted to compliment your ambition. I'm always impressed by the confidence of members such as yourself to tackle unique projects that aren't mere bolt-on applications...makes the reading here fun!

Oh good! I'm glad a few people are watching/entertained, thanks for the feedback and the compliment.



To be honest, I'm never sure how much the deeper technical content is really valued on this site. I enjoy doing this type of projects, and sharing this type of thing, but only to be helpful to someone thinking about doing it, or entertaining for others to read about.


Nice to know a few people find it worth reading about, even though you may never take on such an involved project.

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