Any pics with you bumper off phantom?? Getting a tranny built n when I install it I want a bigger cooler. I like how urs is mounted. Clean set up.

 

I think I sent pics over what we did on the 06.. Lots of trimming in small amounts. The Head light support frame will need some lovin. Small amounts tell the it fits.

 

I got the pictures but it seems that pass side headlight will not go back to stock location with IC pipe in there. Do you have a picture of the headlight back in full postion and IC piping connected?

Well, I just came from the truck and I removed the headlight to check the space and made some measurement.

The 03-06 Silverado and Avalanche with 05+ 34" radiator are impossible to fit 2.5" IC pipe between the headlight and the radiator. My conclusion is that on Silverado truck with 34" radiator, installing the IC with piping routed same as first picture in post#1 is near impossible, unless someone can prove it to me.

chevyboy.520, a member on this forum sent me a good idea of how he fitted the passenger side pipe to mount his IC behind the grill on 04 Silverado. It's similar to this picture.



Here is what he wrote:

"I used 2 "U"s on pass side. One of the turbo, then a 90* coupler to go down, then a pipe for my BOV, then another U to wrap under the frame. Then another 90* to the IC"

 

That is my truck in the pic you posted. I ran it like that for a while then redone the setup like this. I have several pics if you need them I can text them to you.

 

here is a bigger one sorry.

 

. It is doable just very very tight. The pipe wraps around the radiator. Its not a straight shot.
I recommend going with the standard Intercooler for the 99-06 trucks, were its mounted up under the truck. NO trimming anywhere is needed.

 

I don't think it can be done on 03 Silverado truck with 34" radiator. There is no space between the radiator and headlight. If you cut behind the headlight and fit the pipe, the headlight will not got back in place. 03+ Chevy Silverado headlight is much bigger in size than 99-02 headlight.

The driver side will go, with Battery relocated to pass rear corner, as Rick told me and I verifed that by doing measurement on my truck.

As I said, if I had my old 28" radiator, I can cut between the rad and pass headlight and fit 2.5"-3" IC pipe eithout problem. But I don't want to downgrade from 34" to 28" radiator. I could not be happier swapping to 34" and 05+ e-fans.

So, it boils down to either behind the numper under radiator core support or this setup with driver side only IC pipe routed between driver side headlight and radiator (with battery relocated).

 

Thanks for posting this picture. This is exactly how I want to fit my IC.

What size is your radiator? Is it 34" or 28".

When I measured mine, there was no space between the headlight and radiator to fit 2.5" IC pipe even with cutting. If I cut a hole, I will have to chop off the radiator or headlight, or both>

Please post picture of the trimmed area before inserting the ic pipe. Also, what size is your IC?

Did u relocate ur trans cooler? and to where?

What did you have to do on the driver side to fit that IC pipe? what size is it?

I see that you have small battery there to get room for the IC pipe.

 

Take a look at the pic.
You can see were It was trimmed all the way to snap in clip area.
Go under core mount and you will not have to cut anything.
The routing of the piping in the blue truck. Looks like a 28" core. The silicone isn't close to light.

 

You are absolutely right. It's a 28" radiator. I cross checked the picture with my truck. My truck has the 34" radiator.

Also, I removed the radiator top plastic cover to get a good view of where to route the ic pipe at passenger side.

Looks like it can be squeezed under the headlight and behind the turn signal light by cutting a hole there very similar to the picture you posted but little lower to allow the headlight to seat back in it's postion.

Can you post pictures for final product for brhind grill ic that you did?

Also, I want to see a picture of the go behind core mount? How did you route the ic pipes? Inside the chasis beams or outside?

Are they coming out at the bottom like these in this picture?