Powerstroke intercooler install 
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Big ass intercooler. All those wimpy Subaru STi's and Lancer Evo's are gonna get intercooler envy!
 
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Almost wedged in. We'll have to jump on it a little more.
 
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Before I got to his shop John had fired up the plasma cutter and went crazy. He said he got sprayed in the face when he cut through the bumper shock.
 
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Here you can see just how extreme the surgery was. We'll have to reinforce the frame rail on the outside.
 
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He didn't cut through the shock on this side (I'm guessing he did this one 2nd), instead shifting the I/C a bit to the right.
 
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Sitting down where it should. It kind of just rests right in between the framerails (literally) with some LDPE plastic to insulate it to prevent metal to metal rubbing.
 
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The new intercooler pipes under construction. These aren't beautiful but they were done in a hurry with whatever materials I could scrounge up. Spliced together from mandrel bent exhaust tubing.
 
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Radiator support required some relieving. Not a problem since we are using hoodpins. Don't how we're going to fit headlights in! Probably just use low beams.
 
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The hole in the rad support will be plated over. The hood just about touches the I/C when it's closed
 
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Finished intercooler pipes. Still to get are the silicone hoses between the I/C and the pipes. Red cardboard on rad. support is pattern for plate that will be welded there.
 
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Another view of the finished I/C pipes. A little crinkle red paint does wonders. You can see the amount of bend needed to match up to the I/C. Plus they needed to reduce from 3" to 2.5".
 
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Comparison of the SAAB 9000 I/C we used previously. Smaller surface area, smaller tubes, and plastic end tanks.
 
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Another comparison showing the smaller width of the SAAB I/C. This is also a good view of the custom aluminum radiator.
 
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Bottom view shows I/C sitting snugly in left frame rail notch. One tap on the front bumper and it will be crushed! Be careful of those trees, John!
 
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Removal of high beams allows more airflow to I/C (and allows Powerstroke I/C to fit in the first place.) The small square headlights aren't worth a crap anyway.
 
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Right side view shows I/C behind "high beam scoop."
 
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A little better view of the modified radiator support. As you can see it's flatter and allows better airflow to the top of the I/C.
 
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Another view of the rad support and the aluminum radiator held in place.
 
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Nose with hood closed. Kinda sinister!
 

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