Awesome Aftercooler System for Your Supercharger! [Archive]

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GMC K1500 SC

03-24-2002, 02:02 AM

What do you guys think?

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00006.JPG Here's my setup....Aftercooler is off a 7.3L Turbo Diesel as well as the 3 pipes...guy at work gave them to me :) http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00007.JPG Perma-cool 4 tube oil cooler, I also have the oil-stat which by-passed the oil cooler when cold...allows the oil to warm up faster which is a plus! http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00008.JPG This is a metal ring I made up out of some 3 exhaust pipe...had to had a little section to make it bigger so it would go around the TBI unit...I also had a small bead welded on so the hose would not slip off....this will be epoxyed on to the BBK 80mm TBI unit which is already on the truck. http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00009.JPG Side shot...16 elec fan is off a 2001 Ford Grand Marquis with the 4.6L V8...puts out a lot of air...and its a three speed fan...which will allow me to run it on low mode just to keep air going threw everthing but kick on high when the elec temp. stat kicks in or I turn the AC on. http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00010.JPG Side shot of setup...I got the 31 griffen alum. radiator which is 2 thick ($190)...this is about 30% bigger than the trailer package radiator (1 thick, but longer) I had on there....Aftercooler has 3 inlet and outlet pipes. http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00011.JPG I'm going to mostlikely install these 90 degree elbows but I should have extra room once I get the 3 body lift in this week! http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00012.JPG Top view. I'm going to trim off the extra plastic off the shroud and may use some pull threw straps with foam blocks. http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00013.JPG Top view. Man I like the way this looks...looks almost factory :) http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00014.JPG Another shot of the 90 degree eblow 3 x 3.5 with the metal ring in place...fits nice and snug on the stock TBI which is the same dia. as the 80mm BBK. http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00015.JPG 90 degree elbow installed with metal ring...being that this is a low profile elbow it will fit on a non lifted truck! I'm going to leave the water injection on and will also add a nice aftercooler sprayer system which will spray distilled water on the outside of the cooler which will drop the temp another 20 degrees...if ice is added to the bottle even lower....should be good for another 30+ HP even more in the summer!

Hope this give you guys some ideas that have an SC installed or are thinking about installing one! Your feedback is always welcomed :) Ken http://www.kctrading.net/sierra/

Dan Thompson

04-08-2002, 10:29 PM

That looks like to Ford Power Stroke Diesel Intercooler that some of the GN guys are starting to use.

GMC K1500 SC

04-08-2002, 11:50 PM

Originally posted by Dan Thompson
That looks like to Ford Power Stroke Diesel Intercooler that some of the GN guys are starting to use.

Give that man a cigar!

Off a 2000 7.3L turbo diesel...has 3" inlet/oulet...they sell on ebay for $200 new.

Ken

justin

04-10-2002, 12:18 PM

You want to make me one of those things?? :D :D

Where are you going to mount that ??

GMC K1500 SC

05-14-2002, 08:43 PM

Finally got the trans cooler from Summit Racing 30,000GVW Rated...will be installing this very soon now :)

Ken

Figment412

05-15-2002, 11:47 AM

I think you need to something a little bigger :D :D

That should not matter that it is for a turbo, should it? I would think it would be ok for a pro-charger but not sure about a roots type blower. I am just taking a guess on this.

justin

05-15-2002, 11:51 AM

Originally posted by Figment412
I think you need to something a little bigger :D :D

That should not matter that it is for a turbo, should it? I would think it would be ok for a pro-charger but not sure about a roots type blower. I am just taking a guess on this.

Huh?

Ken's got a Vortech. Centrifugal just like a pro-charger...

Figment412

05-15-2002, 12:35 PM

Originally posted by justin

Huh?

Ken's got a Vortech. Centrifugal just like a pro-charger...

I missed that part:dunce:

GMC K1500 SC

06-09-2002, 02:00 PM

Update:

I've got a few more parts to get for the intercooler but it's next of the list to do! I'm going to remove my AC condencer in the front so I can mount the intercooler in the very front, then the oil and tranny cooler after that with the 2" radiator next...this will allow me to mount the radiator in the same location it is in now except I will have to move the mounts in as the radiator is not as wide to clear the intercooler side pipes....I will mount the AC condencer under the bumper at an angle where the plastic splash shield is with a 12" elec fan behind...will have to do some research on which one to run...I have room to run a 15x20+ condencer

Ken

GMC K1500 SC

07-04-2002, 11:09 AM

For anyone who wants to install a front intercooler (big one in front of the radiator) this 3" OD tube is a must have...radius is only 3" (also 3" in between the tubes) This allows the air to flow to the front of the engine to the intercooler....Only thing left to do is welding on some extensions on the Alum. radiator so I can use the factory brackets once they are relocated :)

I am also making up another one of these to sell if anyone is interested...lot of work involved! $75 plus shipping

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0091.JPG

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0092.JPG

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0093.JPG

Here is the rest of the goodies...I also have a HD Hayden 30,000GVW tranny cooler to install....also unlike Lee setup (Blown4x4) on the SC brackets mine sets down at stock height..also a 3" body lift give plenty of room for the tubing :) Intercooler is from a 99 Ford 7.3L Turbo Diesel as well as the tubing....fan is off a 2001 Ford 4.6L Crown Vic. Alum. radiator is from Summit Racing 31" Length. 

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/DSC00006.JPG 

Ken
www.kctrading.net/sierra/

GMC K1500 SC

07-28-2002, 06:22 PM

Had to ship back the seperate oil and tranny coolers as there was not enough room up from...summit racing gave me a full refund no questions asked! I got one of there combo oil/tranny coolers with a 1250cfm fan...see this post in the tech section with pics...

Ken

GMC K1500 SC

08-14-2002, 10:38 PM

Just got the intercooler and radiator back :) today from the shop...as you can see the tubes on the intercooler are about 3" shorter with the brackets cut off and rewelded lower so it will bolt on to the front radiator support...bottom of unit will set where the radiator use to be on rubber cushions...Also on the 2" alum. Howie radiator I had to have the bottom neck cut off at the tank and moved to the right...it use to be in the same angle but pointing to the left...no way was that going to fit!

I will be smoothing out the inside of the inlet and outlet and some of the welds...I'm leaving everything the same color (silver) should be getting it on over the next week or two :)...look out James B.! ;)

I have a lot of left over 3" aluminized turbo tubing left (off a 7.3L turbo diesel) and a close radius 180 degree 3" tube to swing the air around for the vortech-SC for sale if anyone is interested...the 3" tubing is also good to make your own intake system on NA engines...see last pic. 
Howie "all" aluminum 2" core radiator, from Summit Racing $190 31" total length with 27.5" core...fits perfecty between intercooler tubes.
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0142.JPG 
Close up...was facing the other direction...would not clear the drive belts the otherway...in order to cut and weld this up the radiator must be all alum. the Griffin I had was epoxyed...Summit took it back :)
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0143.JPG 
Right side of intercooler...cut and lowered bracket also 3" inlet is now 3" shorter to fit better.
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0144.JPG
Front View.
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0145.JPG
Top View.
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0146.JPG
Close up left side.
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0147.JPG
Close up right side.
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0148.JPG
For Sale: 3" OD aluminized Mandrel bent tubo tubing with HD clamps and hose ends $50 for a set of two plus shipping charges...these sell new for $170 each! I've got four sets of two!

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0135.JPG

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0136.JPG
I can have one of these made up for anyone here cost is just $60 + shipping...you must have this to switch the air to the front to the intercooler 3" OD with a very tight radius of 6" center to center...only 3" inbetween the tubes! (I've already got the piping...just have to have my welder add the 1" ends to it with the lip on each side....let me know as I will be selling all this on ebay and it will be gone <big>fast!!!</big> 
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY0092.JPG>
Ken
Homepage: http://www.kctrading.net/sierra/
Tech Articles: http://64.246.6.99/~admin6/forum/forumdisplay.php?s=&forumid=35 (look up user name: GMC K1500 SC )

GMC K1500 SC

08-29-2002, 11:35 PM

Got both the intercooler and radiator installed...hooked up some top temp. brackets for the radiator until I can get to the radiator shop tomorrow...

Also, after spending and hour at Pep-boys looking over there coolent hose I found two that fit perfectly without any cutting...Hose are 71880 top and 71244 bottom. Last thing to install is the elec. radiator fan/shroud...I can only install one of them...I need to find a shroud that will cover the entire radiator...any suggestions? Radiator core is 27.25 x 18 tall, one flex-a-lite fan shroud is 16x17. Also need to relocate the charcoal canister to the back a few inches and install all the pipes and hoses....which will be this Saturday!...will also have to add a BOV pipe... will mount the MAF between the TBI and the intercooler and the BOV will dump before the intercooler but after the SC

After driving it a couple of days I noticed that just running one of the flex-a-lite fans city temp is up about 15-20 degrees but a little lower above 30mph which is to be expected. Would of liked to run the top fan in the beginning of my first post but there is no room! I've only got 1" of clearance between the flex-a-lite fan and the fan belts....so I will just install a full coverage shroud when I can find one that will fit!

Will keep everyone up todate once I get the rest of the piping done!
 http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY000165.JPG

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY000166.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY000167.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY000168.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY000169.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY000170.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/SANY000171.JPG

Ken

GMC K1500 SC

09-01-2002, 03:10 PM

I still have to do a few things like relocate the maf to the pressure side...that will take out the little tube there just before the tbi. Also going to port the BOV to atomphere....for that nice whoosh noise :) I've also got a bigger valve on hand too....also need to install the two insulators that go in between the rad and intercooler...also sill need a bigger low profile radiator shrould (27" x 19"). Should be in the 13's with my buddy James B. :) Esp. with the upgrade pulley. http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0022.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0021.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0020.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0019.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0018.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0017.JPG
http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0016.JPG

Ken
http://www.kctrading.net/sierra

GMC K1500 SC

09-09-2002, 12:12 AM

All that I was hoping for came true :)

Idle is now a lot smoother and stable also it looks like I'm getting another .5 psi on the boost guage at the same rpms (now 7.5psi) and this is measured at the manifold! Wonder if the MAF flow more with pressure than with suction? I know the suction side is now freeier without the MAF in the way....truck feels stronger and smoother now! Also, it should run a little cooler as any excessive pressurized air is now going to the atomsphere instead of reinjecting it back into the suction side.

Also I was able to just skin back the main wiring loom so I did not have to cut any of the MAF and IAT wires! :)

Also before I was getting some LT lean codes at idle but I know this was because of the location of the MAF and BOV which piping which was not to far away from the sensor...MAF had some pretty irattic readings at idle...but not any more :)

I still need to replace the FMU but I want to do one thing at a time so if there is a problem I will know what is causing it.

I'll post some pics later of the install...looks pretty nice!

Ken

Pretty slick! I still need to cover up the wires but I'll do that tomorrow along with the other wires in the truck...time to do some house cleaning :)

3.5 to 3.5 elbow to maf to 3.5 to 3.0 adapter.

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0023.JPG

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0025.JPG

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0026.JPG

Here is the discussion over at the PA forum too:
http://www.pacific-audio.com/performance/messages/190644.html

GMC K1500 SC

09-11-2002, 11:11 PM

At idle in city driving here are the temps:

Right before entering IC 53.9 C or 129 F
Just before entering MAF 34.3 C or 93 F

At 70mph at cruise speeds on freeway:

50.0 C or 122 F
32.7 C or 89 F.
On the way home tonight 83 ambient temp it was reading 80.2F at the MAF temp sensor probe just before the tbi

From 65 to 85mph max boost 7.5psi...max temps 10mph past shift point.

78 C or 172.4 F.
34.1 C or 93 F.

Ambient outside air temp was 89 degrees...only a 4 degree raise above ambient temp!!!

Anyone want to figure out how efficent (%) the Intercooler (IC) is?

Now you guys running without an intercooler just think how hot your intakes, etc are getting as the high number is what I was running when the SC went stright to the TBI...reason I had water injection...but not any more

I mounted both temp guages on the speedo just below the shift indicator...I'll post some pics later...for $20 each these are great!

Also I double checked both digital temp meters and they were dead even at room temp...they are within 1-2 degrees per there specs.

Also I found out that there was indeed a allen screw in the FMU...I just need some glasses as it way down inside...also have a built in check valve...I met James in Upland where he lives and he confirmed it was there He also took my 2.87" pulley and will mail me the 3.125" tomorrow...really nice guy!

Will be installing the Super FMU tomorrow after work

Ken

GMC K1500 SC

10-05-2002, 10:42 PM

Made up another 3" tube which is longer and got rid of the blue hose which was only 2.5" ID also installed a bigger BOV....still have to shorten the other side to the TBI.

Also notice that I have my temp probe in where the MAF use to be...at cruise speeds on the freeway I run the same temp to about 2 degrees lower just before the tbi :) You NA guys can even do that ;) WOT still is extremely low at 3-4 degrees above ambient.

BEFORE:

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SANY0025.JPG

AFTER:

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/SC-tubing-update.jpg

Ken

GMC K1500 SC

10-06-2002, 12:06 AM

Here are some pics of the update radiator fan...I still have the two flex-a-lite fans for sale for $150 for the pair with one controler plus ups shipping.... email me if you are interested!

Here is the fan I'm using...I got this new from our ford dealer I work for...my cost was just $112 (dealer list is $220)...it flows about 1 1/2 time the amount of air one of the single 150 fans flows...but it's drawing it from a 2" thick alum. radiator...I want to install some rubber panels on the side that you see the core on so when the fan is on it will block air going threw that side but allow air to flow when it's off and running down the freeway...any suggestions here guys?

Notice it's a close fit but I have .5 to .75" clearance :)

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/Update-rad-fan.jpg

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/Update-rad-fan2.jpg

Ken

GMC K1500 SC

10-06-2002, 05:04 PM

Here are the radiator hoses you will need...these fit perfectly without any cutting...not sure what model they fit on....

Also after spending and hour at Pep-boys looking over there coolent hose I found two that fit perfectly without any cutting...Hose are 71880 top and 71244 bottom.

Ken

GMC K1500 SC

11-24-2002, 10:06 AM

We have another fellow member Rob who is building up a 7.3L turbo diesel intercooler setup like mine...will let you guys know how it works out for him :)

Ken

GMC K1500 SC

04-20-2003, 11:22 AM

My friend Rob brought this to my attention as he has copied my setup...I like this dual fan setup! As soon as I get funds I will be ordering one :) Notice that it fits perfectly in between the Howe radiator!

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/Intercooler-Installed!/flex-a-lite-295.jpg

I could not use the orginal single fan setup you saw on the first post as it was way to deep...only way that fan setup would of worked if I took out the AC and relocated the IC deeper.

Ken

GMC K1500 SC

05-15-2003, 09:49 PM

Guy at work is selling the same intercooler that I have plus a set of 3" piping, hoses and clamps...same pipes that I used on my setup for just $200 plus actual ups shipping cost....this will go on ebay soon so I need payment asap via paypal...I've got over 500 transactions with Paypal and a great ebay feedback for those that don't know me :)

Here is my tech article on it:

http://64.246.6.99/~admin6/forum/showthread.php?s=&threadid=12897

I will be personally boxing and shipping it out.

Ken
kctrading
kctrading(at sign)kctrading.net

GMC K1500 SC

06-13-2003, 12:30 AM

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/For-Sale/intercooler-rear.jpg

Link for items on sale (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=2419391544)

Selling this for a friend...I've got the same setup on my truck and will use it on the built 383 engine as well.

Hoping for at least $250 plus shipping but we will see?

Ken

GMC K1500 SC

05-02-2004, 09:19 AM

Anyone try this setup on the Vortech/Vortec engine? If so...post some pics here!

Ken

HegsZ-71

05-02-2004, 01:06 PM

Are you a genius by chance? man there is so much info on this I could read it for days. If I had any idea what you were talking about in half the stuff I'd do something like this on mine. Keep up the good work.

Jokeman

05-02-2004, 01:24 PM

Originally posted by HegsZ-71
Are you a genius by chance?

Evil genius:read::D

GMC K1500 SC

09-01-2004, 11:46 PM

Should have it up and running before the end of Dec 04

Ken

Roc87

11-19-2004, 10:26 PM

Planning a turbo install for my truck and I was wondering where to put the MAF, whether to do like my Grand National and put maf/iac before turbo or put it on the pressure side. I see you liked the MAF on the pressure side better, did you install the IAC on the pressure side too?

GMC K1500 SC

11-19-2004, 10:41 PM

Yes IAC was located just behind the TBI on the rubber elbow....James B. is coming over tomorrow to help get the new 383 installed in the truck! Moving in three weeks got to get it running by next week!

Ken

GMC K1500 SC

12-16-2004, 10:21 PM

Everything installed with upgrade one belt system...had to remake the SC 180 degree tube as the SC setuup a lot higher and closer to the engine compared to the two belt system.

http://james.jaguar.net/kctrading/Pics-of-truck-3-2-02/sany0035-s.jpg

James B. did the welding for me.

Ken

Vortech Jess

01-23-2005, 04:13 PM

check this out. if pic isn't too large.

Vortech V2. powerstroke fmic (same as yours)

bet ya can't guess what psi this puts out :naughty: . stock pulleys

GMC K1500 SC

01-23-2005, 06:40 PM

6 psi? You really need to install the whipple box off the 454 like I have done....when I got mine they were only $99 and that came with a huge K&N filter...see my tech article on this.

http://www.fullsizechevy.com/forums/showthread.php?t=17168&page=2

Ken

Vortech Jess

01-23-2005, 09:21 PM

GMC K1500 SC

01-23-2005, 11:59 PM

thanx. but i don't need that intake. its just a restriction anyway.

heres a few more pics. it looks even better than this, i made a few more improvements. and many more to come

btw. 14+ psi. before adding the fmic, about 10-11 psi stock Vortech kit.
and no, i didn't change any drive pulleys, ever.

oh, and i did ALL the work myself. even the welding & polishing. that box on the throttle body, i made that from scratch.

i thought you would be interested in seeing my engine, as your setup is similar.

Nice...ok...V2...missed that.

I was thinking later of upgrading to a F-trim.

Really no restrictions on the air cleaner as it's all 4" ID through the air filter, canister and 4" flex tubing which has a smooth bore....you after IC temps would go down about 20 degrees more....what compression your running? Also you going to get in on our OBDII programmer group purchase?

Ken

Ken

Vortech Jess

01-24-2005, 06:22 PM

i was thinking of upgrading the a (i think its a) t trim. the next up from an s. but for that money i could just go turbo. and i may in a few years, but i'll use this for now.

ok, yeah, i bet 4" isn't bad. but i like the simple cone.

its an all stock engine, except for what you see. i think its 9.2-1.

thats how i got hear. to check out what was going on with the tunercat, and just started looking around, and found your truck. i have no computer tuning now. unless you consider the HyperCRAP a tuner. it sounds very promissing. but i would like to hear some first hand impressions of it.

your truck hauls, for what it is. your building a new engine, are you using the sfi injection on it ?

Vortech Jess

01-24-2005, 06:25 PM

oh-yeah. where did you get the idea for the powerstroke intercooler ?

GMC K1500 SC

01-24-2005, 10:18 PM

oh-yeah. where did you get the idea for the powerstroke intercooler ?

Some of the Dodge guys were running them in the Caravans!

Also, one of the heavy line guys at work gave me mine :)

Also notice you are running a smaller radiator...Howe makes one that fits perfect and flex-a-lite make a dual fan setup that fits perfect as well...295's I think.

Ken

Vortech Jess

01-25-2005, 06:07 PM

i got the idea from the GN guys.

my radiator works just fine.

btw, what truck do i have ?

85k1500

04-13-2005, 09:51 AM

hey, i work at a perf. shop www.ecmprogrammer.com we use an injector flow bench quite often, throw some injectors in there, set the pressure and do tests, and figured i should suggest that after you install your fmu you check your plugs immediately, a lot of gm injectors like yours will fail and hydrolically lock up, causing an extreme lean condition, i will be making a short video of this shortly, just a heads up. LT1 injectors are reallll bad for it.

GMC K1500 SC

04-13-2005, 08:08 PM