Well, I installed an intercooler from whatever the latest generation of turbo RX7 is. It's a fairly small thing, maybe 8 x 20 or so in terms of core.



I found it quite challenging to install an intercooler when I've already got a tube bumper and a winch... Simply put there was no way to get an intercooler on to my front end without significantly dropping the approach angle or starting over with a new bumper.

As such, I decided to integrate it behind the skid plate. For air flow, I built a scoop - No loss of ground clearance, no IC hanging off ready to be damaged. Note, scoop isn't complete in these photos - but you get the design idea.
I have a slight extension of the skid plate - so some impact to approach angle, but not much.








Plumbing the thing was another challenge - I ended up buying a pretty decent selection of silicone hoses - most of which I didn't use. It's a very tight fit. It can be done by the backyard mechanic, using pre-bent tube (exhaust) and a simple abrasive saw.

Results:
I went to an IC after logging a lot of heat soak in my intake manifold.
After being brought up to operating temperature, my intake temperatures could easily be as high as 180-200 degrees F.
Note, stock intake temps are *not* good either - in the range of 125 degrees F - probably due to the level of heat given off by the radiator and exhuast system.

After installing the IC, I see intake temps of 90-104 degrees. That's a decrease of 70-95 degrees, which is definitely worth while.

I'll post up more photos later...

Nice results, Darin. I've seen a couple of skidplate-mounted ICs, and they each required some complicated piping, so I think that's typical for this location.

The only real problem with this location is the possibility of damage, and the fact that losing an intercooler line effectively stops you dead in your tracks until you get it repaired. Been there, done that, and on the freeway no less, and I don't recommend it. <img src="/forums/images/graemlins/rolleyes.gif" alt="" /> But as long as the exposed parts are adequately protected it's as good a location as you can come up with.

I'd be interested in seeing some better pics when you get it finished.

Cheers,

-Jeff

Whatever works, seams she'll be good.
Perhaps some of that steel screen mesh welded over the exposed IC fins?
Should give you extra protection if you were to drop the front end on a rock, odds are low, but, with my luck? <img src="/forums/images/graemlins/rolleyes.gif" alt="" />

I'd be more worried about damage from road debris.

I need to put a grate on the "scoop" itself, but there isn't any direct line of fire between the road and the IC itself.. Here are additional photos. I think the plate I used is 14GA - whatever it is, it's thicker than the skid plate.

looks nice darin, if that were me i would destroy that thing on my first trip. i have been thinking about where i would mount my intercooler and i had the idea to relocate the radiator or intercooler to the rear of the and plumbing it from there. then use an electric fan. on a 4 runner that might get in the way though. for an ifs truck, the way you mounted that is about the best possible place.

Cool bumper as well! never seen one like that before! <img src="/forums/images/graemlins/cheers.gif" alt="" />

I haven't done any suspension work on this thing, other than fixing the rear sag. I've got a solid axle and an electric locker sitting in the garage, for when I'm feeling ambitious... Solid axle will definitely allow more mouting options.


You might consider an IC from an MR2. They came stock with electric fans and should be good for a 200hp truck.
The biggest negative of this install seems to be that I've still mounted the IC near a lot of hot stuff and it's not as efficient as it could be.

Looks good <img src="/forums/images/graemlins/kewl.gif" alt="" /> That the same bumper you had on it when you stopped by? Looks different for some reason...

Same bumper... Kinda silly on a stock sized truck, but I have used the winch from time to time.