Update 4/2/2025 More Intercooler Details
Here's a photo that was shot during the fitting/modification process for getting a Dodge Cummins intercooler to work for this Lil Red project - and get it all to fit behind the grille.
My reasoning for widening the inlet/outlet was to position the required-new hole through the radiator core support to just outside the boxed-steel section(s) of the core support. This helped to maintain the structural integrity of the core support and maintain access to the core support frame mounting bolts. The downside though is that the widened inlet/outlet required modifying the park/turn light housings. This also required modifying the aluminum tubing used to connect the intercooler to the engine. In my case, I used 3" aluminum agricultural sprinkler pipe as the stock to extend the factory OE piping.
If doing it all again, I might investigate using an aftermarket intercooler core sized for the existing real estate behind the grille while doing my best to maintain the engine's flow requirements and park/turn light assembly clearance. - Jim
By the way, this modification to the intercooler (on both sides) cost $500 at a metal fab shop, and that was on top of the $200 cost of the salvage eBay Dodge intercooler. A new factory Duramax intercooler at the time was $600 through our local dealership. Decisions... decisions...
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