The Permanent Fix:
After repeat offenses of blowing the hot side intercooler tube off our '97 F-350's Spearco charge air cooler, we turned to our friends at Flynn's Shop for a permanent fix...
What Was Happening
Over the summer, we didn't have any issues with this, but due to the warmer air back then we were seeing 45 to 46 psi of boost out of the S468 turbo on the street and at the track. Now however, in the cold, dense winter air we can see 50 psi of boost, and that much boost had proven to be a bit much for this connection point (where the hot side, pre-intercooler, tube connects to the intercooler inlet) on more than one occasion. And, when the tube blew off, it kicked toward the engine, tweaking our power steering line. The last occasion actually bent the truck's A/C line as well. Plus, each time it occurred we were losing a good, spring-loaded, T-bolt clamp out on the highway.
Innovative Fix at Flynn's
While we knew we wanted an intercooler strap to solve the problem, the radiator core support on the OBS Ford doesn't provide much room for a traditional intercooler strap setup to work. After some quick brainstorming, Flynn's came up with the idea of utilizing a 3-inch (od) band-style muffler clamp on the 3-inch intercooler tube, and linking a piece of flat steel between one of the the clamp's tightening bolts and the core support. Now if the tube tries to blow out of the boot, it will have to take the core support with it--which isn't going to happen.
Now to see if we still have a functioning A/C system this spring...