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Discussion Starter #1
I've been running my Scout without a charge air cooler since I did the repower in 2002 and so I figured it was about time for another project. Have always had what I call higher than normal EGT's, it left me without the ability to tow anything with the Scout, so what could I lose?
After much searching and measuring I found that a 92 Dodge CAC would fit in place of the Scout radiator and a 1996 chevy S10 radiator would fit between the inlet/outlet of the Dodge CAC and not contact the fan. The S10 radiator core is only 1" thick and would give me the 1" to 1.25" clearance to the fan. The stock Scout radiator was too thick, the fan would hit the core, thats why the radiator change.
 

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Discussion Starter #2
There wasn't much metal to remove on the front.
 

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Discussion Starter #3 (Edited)
I needed to fix the front seal leak and upgraded to the 94 Dodge front end, alternator, thermostat and belt tensioner.
Only 2 small sheet metal shields were needed to seal the new radiator in, this is the drivers side.
The rivitnuts are for the radiator mount.
I added some sound deadener to the from gear cover and the valve covers.
 

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Discussion Starter #4
The passenger side sheet metal seal.
The CAC mount
 

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Discussion Starter #5
The CAC mount goes here
The Radiator mount.
 

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Discussion Starter #6
The radiator mount installed.
Test fit of the CAC.
 

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Discussion Starter #7
Condenser goes back in.
The top radiator mounts
 

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Discussion Starter #8
The top radiator mount completed and radiator installed.
Fabricating the radiator mounts probably took more that half of the total time for the project.
 

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The new fan shroud.
Added the grid heater for those cold mornings. Still need to wire it up, I'll do that next winter sometime.
 

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Discussion Starter #10 (Edited)
Done. Now you know what I've been doing for the past 3 months, weekends only.
 

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WOW - Nice clean install
 

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Discussion Starter #12

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Discussion Starter #14
nice setup. what airfilter are you running? need one like that on mine with a mudshield!
Thanks,
The air filter is a Baldwin PA2805. A lot of the P30/4BT's had them.
 

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This is a great informative thread. Hopefully I can find a 4bt to use instead of the 6bt currently in my rig. I should have everything else needed to make a CAC work up front.
 
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