Intercooler size?

[LumpyVR4]

Hey all, so in researching intercooler size all I've done is confuse myself. I'm trying to figure out if either of the coolers I have are suitable for my needs or if I should get something else. Based on some things I've read one of my coolers is a good size, and others indicate I need something bigger.

Motor has 270 cams, ported evo 3 mani, ported TD05-20G to 3' dump and exhaust. On the intake side there is a custom air box into 055 AFM on the intake side. I plan on running e85 at 25psi. I'm thinking something sized for 450 - 500hp would be more than enough.

Cooler one, I think is too small.
550 x 200 x 100 bar and plate, 2.5' pipes



Cooler two, might be right according to some
450 x 300 x 75 tube and fin, 3' pipes



According to other things I've read I need 600 x 300 x 75 for good cooling.

Thoughts?

 

[OLDIE]

Surface area is more important than thickness so IMO it comes down to the space available.

 

[PREDATORVR4]

You can fit a 600x300x75 in there fine just lift it up as high as u can to save trimming off abit of the bottom of the front bumper.

 

[bazeng]

I think with the setup you have, try the tube and fin. If you find your intake temps are still high, swap it out with the bar and plate.

My understanding.
Longer core means increased pressure drop. Bar and plate stronger than tube and fin but inferior in flow. Better in cooling. Thickness will impact performance. I've always liked 100mm cores on our cars. 300mm will usually hang low on our cars also.

What bumper you using?

 

[LumpyVR4]

The tube and fin is off the new car. It has an cut out Aus spec bar that has been trimmed for the 450 x 300 cooler. I'm going to remake the bracket to raise to cooler up by an inch to get it inside the bar to protect the cooler and because there is a Jspec bar in my future, but I'm focusing on getting the car on the road first.

I'm thinking this cooler will be OK as it's a street car so won't have extended periods on full boost where it will heat soak. If it was a track car I'd be heading straight for the 600 x 300.

 

[MDK87]

You can only go so far up before the top of the core hits the bar reo (I'm talking about J-Spec bar). I hate under hang, I've got it with my car (600x300).

A larger core will increase dwell time and contact area but also increase pressure drop as Baz said and filling time.
For a street car imo you'd choose the smallest core that will scavenge the heat you expect to generate in the driving conditions you expect to operate it in, without being an impedance to airflow.
Doing so will reduce filling time and pressure drop. The heat sink design also plays a part in how well it can shed energy and as you mentioned the thermal mass is important too.

I'm going to try a return flow intercooler on my VR4, only because the wastegate return ruins any possibility of using a crossflow one.
I'm expecting some heat migration from inlet to outlet but there isn't much I can do about it. I'm just going to run a thermostat controlled water spray.

 

[MDK87]

You can fit a 600x300x75 in there fine just lift it up as high as u can to save trimming off abit of the bottom of the front bumper.

Well maybe I'm just not doing it right haha
Did you have to cut the reo to do that Dean? I don't want to cut the little flaps on the bottom of the bumper skin if I don't have to.

 

[PREDATORVR4]

Na didn't trim the reo it just misses. I cut my flaps off as it sits level with it.

 

[LumpyVR4]

The bottom edge of both the coolers I have has been dinged upward. I'm toying with the idea of this because it's 275 high, not 300. It is ebay though. I'm not sure how much difference there is between something like this and somethine for say an ARE cooler that's $1300.

http://www.ebay.com.au/itm/121695273877?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

 

[MDK87]

Good find ^ 275mm should fit nicely.

 

[LumpyVR4]

Anyone have any thoughts on this?

http://www.ebay.com.au/itm/120713774824?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

After doing more reading I'm looking at bar and plate because it has more thermal mass, which is better for intermittent boosting. The larger thermal mass means it can absorb more heat from the air passing through it, but then it takes a little longer to get rid of it. You boost and heat the cooler, then it cools off while you cruise along off boost.

I'm thinking the centre tank arrangement to better dispurse the air into the core.