ok guys, i put in my powerstroke intercooler, and it didnt take me much time at all. i did it a little different than the rest of you, and saved cutting the top of the core support, the hood, etc. i didnt even have to cut my inner fenders, with 2.5 inch pipes. I used the home mig welder and turned it on high, and blasted right through the sheetmetal around the headlight area, made a nice hole for the intercooler necks to fit in. this took maybe 30 minutes after i removed everything, which didnt take but 10 minutes. the holes werent as pretty as some of the other guys holes, and are square instead of perfect circles, but they will work. I did have some trouble putting on the 3 inch to 2.5 inch hoses onto the intercooler, and ended up shaving the intercooler neck down so they would fit. after this, i just set the intercooler in front of the radiator, and then test fit the header panel. i decided i would just leave the intercooler resting on the shock absorber bumper mounts at their smallest diameter positions instead of cutting the frame and stuff, and it worked. all you gotta do is cut a 90 degree area out of the inner headlight bucket area. like everyone else did, but you remove a little more. what you remove is still covered up by the headlights and the headlight bucket things, the plastic pieces with 2 holes and turn signals. only difference now is that i had to cut less, and there is now a gap between the radiator and the intercooler. i plan on using some plastic or something to fill this gap later on, when summer comes around. right now its showing no difference in cooling. with the fan off, and the 68 degree weather, it was running 160 degrees dead on. im quite happy with this. as for the pipes, the way the intercooler is mounted farther forward, makes the pipes move forward as well, and now the pipes exiting the intercooler fit right between the radiator end tanks and the inner fender. no cutting there is necessary. ill post up some pictures soon.
thanks for all your help on this project, and for sharing the word about the IC!
thanks for all your help on this project, and for sharing the word about the IC!