For the intercooler, I didn't want to keep the factory top-mount position for two reasons. 1) Heat soak from the engine in slow moving traffic is and 2) Getting a decent air feed to and through the intercooler without a (rather conspicuous) bonnet scoop would be very hard. I chose a front mounted design, which given the radiator was taking up most of the RHS of the frontal area, restricted me to using the left area under teh slam panel brace.
Like the radiator, I mocked up an MDF template to see how big I could make it. With very small clearances to the turbo outlet and wastegate actuator, I could manage a overall size of 370W x 180H x 60mm, Assuming that looking front-on, the end tanks are 60mm wide, and the fact that the end tanks are slightly thicker than the core, this gives me a core size/volume of approx 250 x 180 x 55mm and 2.5 Litres. The factory intercooler core is 185 x 185 x 65mm / 2.2 Litres so my intercooler is ~13% larger than the factory (Phew!) and being a front mount, the better air flow and less heat soak will offer a better efficiency.
Because there is no room to have the inlet and outlet to face the sides, it will be a "Back door" design - the proper term - with the pipes both facing the rear. The outlet of the conical shaped pipe that attaches to the turbo is 50mm (actual turbo outlet though is 30mm)) so I have decided to maintain that diameter all the way to the throttle body, then expand to the 60mm throttle body.
Maintaining flow is important so instead of the end tanks being completely square, the design called for an angle on the end tanks and also the inlet/outlet pipe in the middle so that the air is evenly distributed across the height of the core. Now to draw it up on paper and get a quote to fabricate it...
Like the radiator, I mocked up an MDF template to see how big I could make it. With very small clearances to the turbo outlet and wastegate actuator, I could manage a overall size of 370W x 180H x 60mm, Assuming that looking front-on, the end tanks are 60mm wide, and the fact that the end tanks are slightly thicker than the core, this gives me a core size/volume of approx 250 x 180 x 55mm and 2.5 Litres. The factory intercooler core is 185 x 185 x 65mm / 2.2 Litres so my intercooler is ~13% larger than the factory (Phew!) and being a front mount, the better air flow and less heat soak will offer a better efficiency.
Because there is no room to have the inlet and outlet to face the sides, it will be a "Back door" design - the proper term - with the pipes both facing the rear. The outlet of the conical shaped pipe that attaches to the turbo is 50mm (actual turbo outlet though is 30mm)) so I have decided to maintain that diameter all the way to the throttle body, then expand to the 60mm throttle body.
Maintaining flow is important so instead of the end tanks being completely square, the design called for an angle on the end tanks and also the inlet/outlet pipe in the middle so that the air is evenly distributed across the height of the core. Now to draw it up on paper and get a quote to fabricate it...
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