speaking of custom intercoolers
 

Ok all these posts on custom intercoolers has really got me thinking. What do you guys think of this idea. First you'll need two things custom made. First the radiator and then the intercooler. Keep in mind that most kits are about 1300.00. Here's the plan. Get a custom made radiator (about 400-500 bucks). I assumed based on the measurements of k2rd's radiator that the stock one is about 20x18.5x2. The new radiator will be a dual pass aluminum type that measures 23x12.75x3. This leaves enough room for an intercooler that is 23x5.75x3. Now it would be up to you has to what's on top...I'd probably put the radiator on top since it'll create the most heat.

Based on those numbers the radiators surface area will decrease by about 20% but the overall cooling area will increase by 115%..plus the fact that it's a dual pass design (twice the cooling, in a perfect world?????) You'll probably need to do the black magic fan upgrade..I already have. But with both the radiator and the intercooler being the same thickness you can use the fan to cool both and perhaps make a second shroud to cover both units. I have yet to actually run through the calculations to find out if this radiator will actually be more effective at cooling...but I think it'll be promising.
Overall price for this project would probably be about 1000.00 for the cores and endtakes and another 150.00-200.00 for intercooler pipes. So you really aren't going to save much money..but hey you'll have a better radiator and intercooler and a lot shorter pipes with no cutting required. You'd probably still have to relocate or install a mini battery.

If anyone has been through fluids or thermo (I'm taking them next semester) and wants to crunch some numbers..go ahead. But seriously give some input on what you guys think about this.