Originally Posted by Vanimal
The problem with the factory cooler, is running the hoses. I may be mistaken but my radiator looks wider. This does not leave much room for hose/tubing through the radiator support. This is what has me stumped. My plan is to mount it behind the winch bumper and angled up and run the tubes up the sides of the rad. Someday I will get to it, if you can post pics directly many of us are comp. illiterate!
I'm wrestling with that as well, it's tight.
I've only made a little progress in the last week or so, relocated the transmission and oil dipsticks, rerouted the alternator +pos wire.
I ordered some 3" x .06" wall mandrel bent steel exhaust 90's. My plan is to cut large holes in the radiator support uprights, on both sides of the radiator. Rather than making the holes pass-throughs, I'll weld the steel sections of intercooler tubes in place, restoring most of the radiator support's strength.
My 1995 van has 2 engine compartment batteries, the one on the passenger side is very much in the way. I have some Ford battery boxes on hand, as I may have to relocate one or both batteries to the frame rails.
I now have 2 pair of Ford aluminum intercooler pipes, which should give me enough material to make the runs I need. My good friend of 50yrs, who has always done my TIG welding for me, is down recovering from a surgery just after moving, and his shop isn't set up. I'm looking for a local welder who will rejoin my pipes. I have a guy lined up to do the bead rolling of the tube ends, not beading them seems to allow the silicone couplings to pop off too easily. Either that, or I'll buy a tube beader from Jeg's.
I'll post up more pics as I make some significant progress