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Old 01-27-2013, 04:06 PM
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Intercooler options

Getting to the point in my build when I need to start looking at intercoolers. Just wanted to know what others are using and where they got it. I am installing a Cummins 6BT in my 85 Wagoneer. If you can, post some pics as well. Thanks.
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Old 01-27-2013, 11:47 PM
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I used a Mishimoto in my M715. Had to cut the inner fenders for the plumbing, but it fits. I'll have to look up the part number.
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Old 01-28-2013, 07:15 AM
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Quote:
Originally Posted by poolmike
I used a Mishimoto in my M715. Had to cut the inner fenders for the plumbing, but it fits. I'll have to look up the part number.

Poolmike, would definitely appreciate it if you could post the part number. Thanks.
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Old 01-28-2013, 07:23 AM
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I read this thread yesterday and spent some time thinking it over before replying.

The Dodge OEM intercooler that came with my donor engine was pretty easy and straightforwad to install, once I figured out how to do it.

I think no matter which IC you end up using would require some trimming of the front valence, but if you used the Dodge one, and turned it upside down, you probably wouldn't have to mod it like I had to.

I'm interested to see what you come up with.
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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290
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Old 01-28-2013, 06:34 PM
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Quote:
Originally Posted by Resbum
I read this thread yesterday and spent some time thinking it over before replying.

The Dodge OEM intercooler that came with my donor engine was pretty easy and straightforwad to install, once I figured out how to do it.

I think no matter which IC you end up using would require some trimming of the front valence, but if you used the Dodge one, and turned it upside down, you probably wouldn't have to mod it like I had to.

I'm interested to see what you come up with.

After a day of beating my head on the wall and looking at the stock Dodge intercooler, I have figured out how you were able to mount the Dodge IC in your J20. The J20 has different body mounts over the Wagoneer effectively giving it what appears to be a 1.5" to 2" body lift over the Wagoneer. In order to mount the intercooler in a Wagoneer, you would have to install a 2" body lift. There is only 14 of clearance between the frame rail and the lower valance support that helps hold the two pieces together.
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Old 01-28-2013, 07:26 PM
budojeepr budojeepr is offline
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Quote:
Originally Posted by poolmike
I used a Mishimoto in my M715. Had to cut the inner fenders for the plumbing, but it fits. I'll have to look up the part number.
This thread got me thinkin' again about an IC. Poolmike, how did you mount it? Got pics up here somewhere?

Thanks!
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Old 01-29-2013, 08:56 AM
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Running seriously late for an appointment. I can post more detail if needed later.




The front of these tabs bolt to valence


You can see the new header top and top plate back on in this pic.
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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290
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Old 01-29-2013, 08:57 AM
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Save tabs, straighten them, weld back onto valence
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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290
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  #9  
Old 01-29-2013, 10:17 AM
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The first generation dodge CTD intercooler fits very well with some minor inner fender massaging.
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  #10  
Old 01-29-2013, 02:53 PM
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Resbum, Thanks for the detail on the modifications. This definitively clears up a lot of questions that I had. I think I am going to go this same rout and run the Cummins intercooler. I think I am going to invert it though. We will see.
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Old 01-30-2013, 08:50 AM
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Glad it helped. Sorry for the earlier confusion. Yesterday I was in a hurry. Here's some more info. If you can weld aluminum it will cost nothing but time. Otherwise, you need to decide how much welding you're willing to pay for.

I decided to add these filler pieces at the last minute. With them and the round covers back in place none of the header tanks can be seen and it just looks like an extra wide radiator behind the grill. I trimmed the valence to the inside edge of the header tanks. That barely left three of the four screw holes for remounting the round covers. (trying to preserve "stock" look as much as possible)


This is a test fit of the grill during early fabrication. Imagine the round covers back on. With everything painted a satin black it takes a knowing eye to catch the mods.


I would highly recommend mod'ing the inlet and outlet of the IC. If you're seriously thinking of inverting the IC you could also trim the header tank down like the red line shows. You would need to move the mounting/support studs to the other end of the header anyways, so that wouldn't pose a problem.


Another thing I thought of yesterday was that I intentionly pushed the IC as far forward as I could possibly get it to make room for the trans and oil cooler to mount between IC and radiator. You could probably gain 1" of clearance in front of the IC by moving it back. This would most likely greatly reduce the amount of trimming on the valence needed.



If you go with the Dodge IC, and use the the things I learned before you start, you'll probably end up with a super clean looking install. A lot nicer than mine, and what I envisioned mine was going to look like. I'm seriously looking forward to how yours turns out.
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Quote:
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290

Last edited by Resbum : 01-30-2013 at 08:58 AM.
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Old 01-30-2013, 09:02 AM
SJTD SJTD is offline
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Have you looked at the older Dodge I/C ('91-'93?)? I believe it's not as tall. Core is around 30.5" x 12.5". Overall width is about 37.5".

Looking at Resbum's thread I was thinking "that doesn't look like mine" until I realized mine's the older one. Haven't tried to install it yet.

If you want a picher I could get one Saturday when I get home.


Edit: After reading the subsequent posts I see that I missed Mikel suggesting this above. My apologies for not referencing it.
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Old 01-30-2013, 09:46 AM
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After Mikel and SJTD both mentioned the earlier Dodge IC I got curious and went looking for a pic of one. I only found one image and the poster said it's for a 92.

SJTD, I don't know about ross, but I'd like to see some pics of yours.

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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290
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Old 01-30-2013, 10:01 AM
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Mikel and SJTD are correct, those intercoolers are smaller and would fit nicely in the valence, when I get to the shop tonight I can take a few pictures of the rotted one I have with dimensions if you would like.
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Old 01-30-2013, 10:10 AM
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Quote:
Originally Posted by rwjohnstone
Mikel and SJTD are correct, those intercoolers are smaller and would fit nicely in the valence, when I get to the shop tonight I can take a few pictures of the rotted one I have with dimensions if you would like.

Yes, post up some pics. It is good information for all of us looking to do it.


Resbum, I am a good welder, but I cannot weld aluminum to save my life. Thankfully I have a friend that can weld aluminum very well and is a sales rep for Victor Technologies and has access to all the latest and greatest welding equipment and best of all, he owes me a couple of favors.
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Old 01-30-2013, 11:20 AM
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Resbum,
I think this is the first picture that you posted with the grill covering the radiator. For the longest time I thought It was going to have a Rhino grill mounted to the stock valance. Then you started notching it and I was confused.

I'm waiting for my radiator to come in later this week, but plan on using the stock 94 ram intercooler. It fits fine when its held up to the truck right now. It should have enough clearance top and bottom with the 2 inch body lift.
The cummins is a tight fit on height between the hood and sway bar without the body lift. Not sure how you guys do it.

My truck is a 82 wagoneer, but will have a 89 grill (I just like that one better). The front valance will definitely get trimmed during install to fit the camaro radiator, ac condensor, intercooler, and trans cooler.
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Old 01-30-2013, 11:43 AM
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I wanted to also add that Mercenary Offroad built a cummins wagoneer that was in a magazine. They have an album on their facebook account. It looks like they used a intercooler from frozen boost. The entire center section of the valance was cut out probably for quick installation.

http://mercenaryoffroad.com/
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Old 01-30-2013, 09:48 PM
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This is the after cooler that came on my 92 dodge:







1.625" thick



37" long



12.75" tall



2.5" ports



34.5" port centers




I hope that helps good luck!
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http://www.ifsja.org/forums/vb/showthread.php?t=150066

1979 CJ-7 (s) - Status: Dismantled Hibernation

1981 J-10 - Status: Parts? Daily Driver? Lawn Ornament?

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Last edited by rwjohnstone : 02-01-2013 at 10:23 AM.
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Old 01-30-2013, 10:31 PM
poolmike poolmike is offline
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Quote:
Originally Posted by budojeepr
This thread got me thinkin' again about an IC. Poolmike, how did you mount it? Got pics up here somewhere?

Thanks!


I'll get some pics. This is one part of my truck that I did not install. While I was fabbing up engine/trans/t.case mounts, I took the rad support/valance to MD Racecars in Ivyland PA and said "Call me when there is an intercooler wedged in there, 3" plumbing"

Basically, there is some round tube running along the top and bottom of the cooler. The top tube bends up at the ends and bolts to the rad support, same with the bottom, bending down.
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Old 02-01-2013, 08:17 AM
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Interesting info in the last few posts.
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