2nd gen intercooler in a 1st gen

[cummins21]

well i just got done putting a 2nd gen intercooler in my 91 d250. it took me about 2 hours to do it. i was really easy to do. all you need is 2 flat head screw drivers,1/2 socket or wrench, grinder, tape measure and a sharpie. i took some pics as i did it there not the best pics but you will get the idea.

first thing i had to do was pull this big bumper off that weighs a ton.



next i pulled the grill off and removed that white part that helps hold it on.



then i did some measuring and cut my holes out.



then it was time to put it in. i still got to figure out how to bolt it up but its in.


this is the driver side hole not the best cut in the world.


and the passenger side hole.

 

[ramhunter9]

Cool

 

[cummins21]

it is. i found a cheap twin setup thats next on the list should have it monday and put in my truck on tuesday. cant wait

 

[Rogan68]

it is. i found a cheap twin setup thats next on the list should have it monday and put in my truck on tuesday. cant wait

there's no such thing

 

[cummins21]

oh but there is i paid $700 for the setup with the hotpipe and every thing. its all home made.

 

[Rogan68]

that's cool. what's the turbo(s)?

 

[cummins21]

the guy said it was a HT3b over a wh1c. i have heard of it but never seen it till he sent me pics. i hope it works out.

 

[Uncle Ugly]

WH1C is nothing more than a HX35 in its early form.
Just make sure the WH1C has a small exhaust housing on it or it will bea lag pig to get lit.
That combo has been around along time and it is fairly durable.

 

[cummins21]

the wh1c does have the small housing on it. it will be here tomorrow i will post pics as i am putting it in.

 

[Mopar1973Man]

I got a buddy in New Meadows, ID with a 92 that wants to upgrade to this... I've sent him a email with a link to the page hopefully his watching the thread...

 

[WhiteExpress]

If you still have it apart, drill out the corners on those sheet metal cuts.

A sharp corner like you have will lead to a tear in the sheet metal. Fairly easy to do (though easier if done BEFORE cutting).

Twin Turbo Gen I Cummins? SWEET!

 

[Rogan68]

good point

 

[cummins21]

thanks i did not know that i will go back and fix it. well my twin set up came in today. the turbos are in ok shape not like he said(great shape) but they are going to be nice to have. i will post pics as i go putting it together.

 

[WhiteExpress]

No problem. I learned a lot being a mechanic for an offroad shop. That boss was always on my ass about something.

 

[cummins21]

so i should just round the corners off right.

 

[WhiteExpress]

so i should just round the corners off right.

Yea, you don't want any square corners. Drilling them out will help prevent cracks.

 

[cummins21]

got the twins in and going. went about half a mile and popped a head gasket. i guess its time to tear down on her and do some more work. i just wanted it to last longer than that. any body got an idea of a good place to get a good head gasket i guess there all the same i dont. any input would be great.

 

[Rogan68]

head-stud time! LOL What boost pressures were you seeing prior to poppage!


And where's the damned pics?!!

 

[cummins21]

well guys i know you all wanted to see pics of the twin setup. but i no longer have the truck i found a deal that i could not pass on. i am the proud owner of a 2001 dodge 1500 auto. i really love this truck. i got a hell of a deal on it to. it only has 47,462 miles on it. i traded my cummins and the guy gave me $2000 so i had to do it. here is a pic of it.