1042700 BD Diesel Xtruded Charge Air Intercooler for 1999-2003 Ford 7.3L Powerstroke

When it comes to aftermarket intercoolers, all are not created equal. BD Diesel has done extensive product testing and research in order to ensure they are bringing us the absolute best intercooler to the market. 

The main thing they noticed when testing the factory charge air cooler as well as other brands of aftermarket intercoolers, was that the stuffed tube design
 
This material is brased into the charge air tube, after years of heat and pressure, the brasing will fail and the stuff tube material will break lose and end up compressed to one side of the charge air cooler. Now your intercooler is no longer allowing air to be cooled through that failed chamber. As more and more chambers fail you will start to notice your intercooler boots blowing off all the time, excessive EGT's (Exhaust Gas Temperatures) and a massive loss in power. 

BD started playing around with a costly proceedure called Micro Extrusion,
 
Micro Extruded Tube design is for applications producing 20-100 psi of boost pressure and inlet temperatures of 500°F+. The tubes have a 0.025” wall thickness and designed enhanced inner fins that add to performance and already strong support structure resulting in a 95% heat conductivity transfer. No cracking or separation occurred when tested at over 400 psi.

Higher turbo boost pressures results in lower EGT’s.

The lower the turbo boost pressure drop across the CAC (inlet vs. outlet) the higher the volume flow — the more volume of air that can fl ow through the CAC and the higher the turbo boost pressure will result in lower exhaust gas temperatures (EGT). BD’s Xtruded  CAC’s are designed for performance diesel engines.