danny04mystic
Member
- Joined
- January 29, 2023
- Messages
- 10
- Reaction score
- 9
- City, State
- Mount Airy, Maryland
- Year, Model & Trim Level
- 2017 Explorer Sport
Been wanting to do an intercooler upgrade but for $1,000 and you need to do some cutting anyway, I decided to go a different route. I think the install went extremely well, and the whole setup cost me about $300-$320 or there abouts. I'll post pictures and materials I used as well as a link to a video I saw that gave me the idea to do the same.
Video here:
I went with a bar and plate intercooler from CX Racing, I've used this company in the past for a couple heat exchanger setups on my 04' cobra and the quality was top notch. So I figured out the dimensions I could fit and found one from them that seemed like a good fit, and it was perfect! I considered other brands such as the Treadstone and Mishimoto but I thought I'd go with a company I've dealt with before knowing it would be good quality for less and accomplish the same results.
CXRacing-Front Mount Universal Aluminum Intercooler 28.5"x8"x3.5", 3.5"Core: 22x8x3.5
https://a.co/d/34qQ8E4 ($222.41)
Other parts required were 2, 90° elbows. 1st one is 2.5" x2.5". 2nd one is a reducer elbow 2.5" x 2.25". Then 2 couplers, 2.5" and 2.25". Plus 4 clamps.
Ronteix Universal 90 Degree Elbow Reducer Silicone Hose ID 2.5 Inch to 2.25 Inch (63MM-57MM)
https://a.co/d/2H1XogK ($18.99)
90 Degree 4-Ply Elbow Coupler... Amazon product ASIN B095LT38TG ($20.99)
Mishimoto Stainless-Steel T-Bolt Clamp, 2.13" (54 mm) to 2.44" (62 mm)
https://a.co/d/e4TAVAm ($5.95)
Mishimoto Stainless-Steel T-Bolt Clamp, 2.36" (59.99 mm) to 2.68" (68 mm)
https://a.co/d/2SIZwog ($5.95)
AotoKoop Universal OD 2.5" (63mm)... Amazon product ASIN B0BCTZZLFF ($12.99)
AotoKoop Universal OD 2.25"... Amazon product ASIN B0BCV6MZHQ ($11.99)
Total for everything, (before tax, 6% for me in Maryland) $299.27
My total was $317.23.
As in the video, I did have to cut some bits of the composite core support to remove factory intercooler, and make room for new one. Pretty straight forward and using my multi tool was quick work. Core support has lots of structural support so I wasn't worried about cutting a bit from it. It's very sturdy and still is after cutting some out for the install. I also modified the horn bracket, cutting off the bend to make it flat, drilled a couple holes and figured it in place. Intercooler also came with bolts and a couple flat brackets which I bent in an "L" and secured to intercooler with provided bolts then rivited the brackets to the core support. I had to trim the intercooler outlet 90° a tad but I bought that long one so I would have enough length to reach the coupler to the throttle body. The entire install is a very easy project. You do need to obviously remove the front bumper cover and there are plenty of how to's already so I won't get into any of that.
If anyone has any questions feel free to ask and I'll try to assist best I can. But I really just wanted to share my install and show an affordable option for us 3.5 Ecoboost owners that may want to do this without breaking the bank. There's only one vehicle specific intercooler upgrade that I'm aware of and I know there are other threads on custom installs but I don't think it's in depth as this. Also you can use whatever intercooler you want using this process if it's demensions are close. But I can tell you this one I used is a really great fit.
For those that are wondering, (I know it was coming lol)....
With mods in my sig, using canned 93 performance SCT tune from my x4, I'm hitting just under 15 psi at wot, iat was reading about 10-15° above ambient. It was almost 90° today and was around 110° after a wot pull. But I saw it after stopping and idling for a sec and I was really only looking for drop psi. I spiked just over 15 psi with the factory unit, and 14.79 psi after. So boost drop is minimal. Truck felt like it pulled much harder though all the way through the rpm range as before it would fall off in higher rpms. So it's definitely an improvement. And will be even better when I get a real tune and install my 3 bar map, thermostat, and 1 stage colder plugs. Still on stock exhaust but that's coming later for me.
I hope this helps some guys out there that are wanting this upgrade, don't be afraid, it's pretty easy if you have some mechanical ability. You can do it!
Video here:
I went with a bar and plate intercooler from CX Racing, I've used this company in the past for a couple heat exchanger setups on my 04' cobra and the quality was top notch. So I figured out the dimensions I could fit and found one from them that seemed like a good fit, and it was perfect! I considered other brands such as the Treadstone and Mishimoto but I thought I'd go with a company I've dealt with before knowing it would be good quality for less and accomplish the same results.
CXRacing-Front Mount Universal Aluminum Intercooler 28.5"x8"x3.5", 3.5"Core: 22x8x3.5
https://a.co/d/34qQ8E4 ($222.41)
Other parts required were 2, 90° elbows. 1st one is 2.5" x2.5". 2nd one is a reducer elbow 2.5" x 2.25". Then 2 couplers, 2.5" and 2.25". Plus 4 clamps.
Ronteix Universal 90 Degree Elbow Reducer Silicone Hose ID 2.5 Inch to 2.25 Inch (63MM-57MM)
https://a.co/d/2H1XogK ($18.99)
90 Degree 4-Ply Elbow Coupler... Amazon product ASIN B095LT38TG ($20.99)
Mishimoto Stainless-Steel T-Bolt Clamp, 2.13" (54 mm) to 2.44" (62 mm)
https://a.co/d/e4TAVAm ($5.95)
Mishimoto Stainless-Steel T-Bolt Clamp, 2.36" (59.99 mm) to 2.68" (68 mm)
https://a.co/d/2SIZwog ($5.95)
AotoKoop Universal OD 2.5" (63mm)... Amazon product ASIN B0BCTZZLFF ($12.99)
AotoKoop Universal OD 2.25"... Amazon product ASIN B0BCV6MZHQ ($11.99)
Total for everything, (before tax, 6% for me in Maryland) $299.27
My total was $317.23.
As in the video, I did have to cut some bits of the composite core support to remove factory intercooler, and make room for new one. Pretty straight forward and using my multi tool was quick work. Core support has lots of structural support so I wasn't worried about cutting a bit from it. It's very sturdy and still is after cutting some out for the install. I also modified the horn bracket, cutting off the bend to make it flat, drilled a couple holes and figured it in place. Intercooler also came with bolts and a couple flat brackets which I bent in an "L" and secured to intercooler with provided bolts then rivited the brackets to the core support. I had to trim the intercooler outlet 90° a tad but I bought that long one so I would have enough length to reach the coupler to the throttle body. The entire install is a very easy project. You do need to obviously remove the front bumper cover and there are plenty of how to's already so I won't get into any of that.
If anyone has any questions feel free to ask and I'll try to assist best I can. But I really just wanted to share my install and show an affordable option for us 3.5 Ecoboost owners that may want to do this without breaking the bank. There's only one vehicle specific intercooler upgrade that I'm aware of and I know there are other threads on custom installs but I don't think it's in depth as this. Also you can use whatever intercooler you want using this process if it's demensions are close. But I can tell you this one I used is a really great fit.
For those that are wondering, (I know it was coming lol)....
With mods in my sig, using canned 93 performance SCT tune from my x4, I'm hitting just under 15 psi at wot, iat was reading about 10-15° above ambient. It was almost 90° today and was around 110° after a wot pull. But I saw it after stopping and idling for a sec and I was really only looking for drop psi. I spiked just over 15 psi with the factory unit, and 14.79 psi after. So boost drop is minimal. Truck felt like it pulled much harder though all the way through the rpm range as before it would fall off in higher rpms. So it's definitely an improvement. And will be even better when I get a real tune and install my 3 bar map, thermostat, and 1 stage colder plugs. Still on stock exhaust but that's coming later for me.
I hope this helps some guys out there that are wanting this upgrade, don't be afraid, it's pretty easy if you have some mechanical ability. You can do it!
