Intercooler Design

[banger68]

I'm making an intercooler out of 3 cores.




Should the tanks slope down to the end or be even? What size should the tanks be for good flow?

[cordes]

It seems like most of the major manufaturers slope them down toward the end.

I would just make the tanks slightly larger than the OD of the piping to be used, but that is once again just based off of what I have seen.

[8valves]

Yes, give them a slight taper, perhaps 10*

I would say the diameter should be regulated by inlet size. Start at the inlet/outlet size (in height of the endtank, obvisouly a bit taller than the actual inlet/outlet size) So if you're using 2.5" pipes start there and then work your way down from there in accordance to the taper you use. That's what I would do at least.

Aaron Miller

[John B]

I think the absolute ideal is inlet/outlet at opposite ends, but that's getting really picky.

[altered7151]

I think the absolute ideal is inlet/outlet at opposite ends, but that's getting really picky.

I agree. Air is always going to take the easiest path to its outlet, so if your inlet/outlet is on the same end, its going to resist going to the opposite end of the intercooler, so you'll get heat soaked quicker on the inlet/outlet end. If you have them on opposite ends, any path through the intercooler is the same distance/resistance, so you'll get better flow. BUT... then you're dealling with alot more installation issues.

[Dave]

http://www.are.com.au/feat/techtalk/intecoolersMR.htm A great read for intercoolers. Taught me everything I know.

Also what material will you be using? If you're using aluminum I hope you can tig weld yourself. If not it will more than likely cost more to build it than buying a good NPR or Mishimoto intercooler.

[banger68]

I have a friend Tig welding it up for me.