Few screen shots of the vid I made, ill see if I can get it up loaded yet, this is before and after the intercooler. As you can see at 1 psi they are both dead on with each other. I used one of these, the dynos, the one in the cab, and checked the map sensor, all confirmed a peak boost of 14 inside the intake manifold, it just touched 23 and 19 as we let off. It pretty much go's through two 90s and into the tb after the second gauge reading, I just couldn't get my head around this, only thing I can think of is the tb closing and ecm not shutting it down

 

That's a 760hp rated threadstone intercooler btw, dout the engine is making quite that yet. Close probably.

 

4psi drop across the intercooler isn't bad but the 5psi drop between it and the manifold would be concerning. Similar information with the manual gauges at IC out and manifold would be useful. Shouldn't be too difficult to tee into the manifold somewhere. If the throttle is being forced closed, you'll see it on the TPS. If not, and if its a cable throttle, it would require a stretching cable and two faulty position sensors for this to occur. For an electronic throttle, a discrepancy between desired throttle position and actual throttle position will immediately drop the truck into REP. So those things are unlikely. I'd double check data with the manual gauge on the manifold.

 

Any indication of a boost leak between intercooler and intake manifold??

 

Smokeshow, that's what I was thinking aswell, we have had it before on a turbo engine where it was kicked into reduced power cause of the tb, this one has never done it.
We did pressure test the entire cold side, only thing I have not done is pressure test the intake itself. Which was going to be my next step but I just wanted to see if this was normal or not before pulling the valve covers.
Also I did put this same gauge on the pressure port but I didn't video that one as I had another guy watching that, he just informed me it was 14.
I will have John log the throttle position to see if it stays open, and also loosen up the intake rockers and do a pressure test to see of I find anything.

 

My treadstone vertical flow intercooler was showing 160 inlet temps on the dyno from a billet S480 at the top of the pull. I do not have any pressure drop data to share though.

I am considering going with an air to water intercooler with a quality core if I can find one to package under the hood.