I finaly got all my parts for an intercooler install and decided to to a little write up on it.
With this install you WILL NOT be able to retain you're A/C condensor also with this install I flipped the I/C upsidedown
Tools you'll need
Socket set and rachet with a few extensions,a couple screw drivers,drill with assorted bits, sawzall wit a sharp blade, a sharpie, and a tape measure
Parts you will need
1st gen intercooler,1st gen piping, 8 2 1/2" t-bolt clamps or constant torq clamps, 1 2 1/2" v-band clamp, 1 90* v-band elbow, and 4 2 1/2" hump hose boots
First start by removng the Headlight bezels, grille insert, outer grill shell and lower filler panel
Next remove the radiator and A/C condensor if equipped
Now measure 7" down from the bottom side of top of the core support and make a mark, now measure 5 1/4" down from that mark and make another mark, now measure 3 1/2" over from the radiator opening in the core support and make a mark, and repeat on the other side of the support
Once you have your core support cuts laid out you can go ahead and fire up the sawzall and start hacking
Some additional trimming may be required
Now that you have your holes cut in you're core support you can go ahead and and start fitting you intercooler
Now establish where you need to drill your mounting holes (I just held the cooler where it looked centered and marked it with a sharpie) once this is done you can go ahead and drill the holes
You can now measure the space between the core support and the mounting tabs of the cooler, make a note of this measurment and measure the other side, make a note, now you can go cut you're spacers out of some pipe or whatever you got layin around(my measurements were 1 13/16 on the pass side and 1 1/2 on the drivers side
Once you get you're spacers cut you can bolt the cooler in place( remember to put some thin strips of rubber between the cooler and the core support)
I used some 3/8 bolts 3 1/2" long and used fender washers.
Now you can hook up all you're plumbing
Next you will have to trim the radiator mount to clear the inlet and outlet of the cooler
After this is done put the radiator back in the truck
I will post more tomorow after I trim the lower filler panel and get the grille installed in the truck