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Senior Member
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2,819 Posts
Discussion Starter #1
The previous owner of my truck did a real hack job in several areas. I have been trying to track them all down and get this truck repaired properly. This is my latest disaster here. He installed a three inch body lift and had to cut bigger than necessary holes in the radiator support for the intercooler. The problem is it looks as though he used a ball peen hammer and a reciprocating saw. The sharp edges have cut through the boots on the intercooler tubing and obviously caused problems with my turbo. He also cut up the structural support of the piece. So my plan is to clean up the cuts, then stitch in some flat steel that I will roll to be a bit larger diameter than the tubing. So the tubing will be running through a tunnel. I will make sure I weld into the support and reinforce the weakened areas. I will then weld on tabs that will also limit the movement of the tubing from the intercooler. I also have to move the radiator down three inches so I can install a stock fan shroud. The will be easier than it sound. There is a lot of room for adjustment and the lower portion will not require that much modification. After all the finish welds are grounded smooth I will paint it to match the truck.

Oh yeah, the only problem I have right now is the flat steel I have is a bit too thick. I am going to try and source some scrap piece that is a little thinner and easier to work with
 

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Junior Member
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343 Posts
That IS some serious hacking. Let us know what it looks like when you have it all patched up.
 

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Dually Club #3
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2,674 Posts
You might want to look at a company to buy a whole new core support. LMC has some good parts at a really good price. A new support would be much better then trying to fix that mess you have.
 

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Dually Club #3
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2,674 Posts
Dont know what year you have but it looks like an OBS. I found the radiator core support for that truck on LMC for $189. The SD core support is $199. Both are very inexpensive.
 

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Senior Member
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2,819 Posts
Discussion Starter #6
Actually, I have a very nice core support from a donor truck I have sitting not more than ten feet from that truck. But the issue is I still need holes cut for the tubing from the intercooler. So I figured instead of cutting up my other radiator support I may as well patch up this one. The holes are in the right place, they just look like a blind dyslectic retard with one hand and three fingers cut them.
 

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Dually Club #3
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2,674 Posts
Ok I see. I guess you could find some sheet metal that is the same gauge as the core support and make some patch panels using your good core support as a guide. Then once installed you could nicely cut holes in the patch panels for your tubing. You could also get some weather stripping to cover the exposed metal in the new hole to keep the new boots from getting cut.
 

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Senior Member
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Discussion Starter #8
I am going to hit up some friends for sme thinner scrap tomorrow. I like your weather stripping idea.
 
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