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Go to www.bellintercoolers.com they've got some pretty good tech data there. Sounds like; Keep the turbo to intercooler and intercooler to manifold plumbing short, the intercooler core tubes should have pretty close to the same total cross-section as the tubes between it and the turbo and it and...

Absolutely right on the turbo high temps. A heat shield would definately help with radiated heat but a good portion of it is conducted through the housing itself. i.e. Warnings to idle engine after long hauls or pulling hard. Must be confusing to the turbo when it's turbine is wrapped to keep...

I'm never shy about asking questions if I don't have an answer and I've a diesel mechanic that's real sharp as to what happens when and why. Will run the idea by him and report back. I'm thinking heating hot air hotter by 40 degrees or so isn't near as good as heating cool air hotter by 40...

Sounds like a worthwhile project though I think there may be more than just plumbing one in. Reason I say that is; my Cummins turbodiesel is an intercooled engine. I put the engine into a non-intercooled Dodge and was amazed at how gutless it was. Are intercooled engines "de-tuned"? Would it...