2015 Product
BD 2015-2016 Fall Catalog

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Xtruded Charge Air Coolers
Cast end tanks with struts

A Breath of Fresh Air...

BD’s free flowing Charge Air Cooler (CAC) - or intercooler - design with streamlined external air passages improves engine cooling while offering less fan noise and less blade resistance, plus, improving engine power and efficiency of the radiator and air conditioning heat exchangers. Designed through testing at 100+ psi turbo boost pressure and 500°F turbo outlet temperatures, our extra thick cast end tanks with support struts have integrity and long life without ballooning and cracking.

**Other’s Stuffed Tube CAC


Stuffed Tube designs are commonly used on stock applications with boost pressures of 20-40 psi and 200-300°F inlet temperatures. The tubes have a thin wall and 82% heat conductivity transfer. Higher boost pressures and temperatures will cause breaking of fin-to-wall welds resulting in tubes ballooning and reduced heat transfer.

(**Others - You know who you are!!!)

BD’ s Micro Extruded Tube CAC

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.

Product Warranty 1-Year Parts
  • Available Makes
  • Chevy
  • Available Engines
  • 2001 - 2010 6.6L
  • Available Transmissions
  • Automatic
  • Manual
Product Rating
CloseOnline Reviews:
  • Nov 30, 2010
    Installation: 5
    Peformance: 5

    Mine works as advertised and installation was pretty easy, I did it.

    Reviewed By: Ken
  • Jan 18, 2010
    Installation: 4
    Peformance: 5

    I have finally installed the intercooler on my 2005 LLY during the holidays. It was -10 * and windy - thought I might freeze to the truck. The install went fairly smooth- had to take off whole front of the truck and it was alittle tough to wiggle the intercooler into mounts. The one thing that I did not know going into this was that it moves the radiator 1" closer to the fan so that fan and waterpump removal will be much more difficult. I could not beleive the difference in overall dimensions and it wieghs at least 2 x as much- great product - money well spent. I have seen the EGT's drop by 150* driving the same roads and hills. Also takes alittle longer to warm up as there is more air flow threw the front of the truck.I did not notice any increase in turbo lag or any codes with this upgrade . I am still considering a turbo upgrade, fuel pump and maybe EFI for later but for now I am happy with this truck so far. Thank you again for all your help.

    Reviewed By: JamesG

1042600     2001-2005 LB7/LLY Duramax 6.6L
1042610     2006-2010 LBZ/LMM Duramax 6.6L