intercooler too big?
 

600HP Garrett High Density Intercooler Core w/ATP Cast End Tanks : atpturbo.com

is this intercooler to big? current setup probably only makes 350hp and might see a max of 500hp in the future.

Not really. The only downside (that I know of) to having an intercooler that's "too big" is that it may cause a slight drop in boost pressure (your turbo is making 10psi, but your intake only sees 9psi) and/or a bit slower response. Though, honestly the response would have more to do with the length and amount of curves in your piping.

The physical size of your IC will obviously help out with how much it cools your intake charges, but ducting and access to cold air will also play a HUGE role in that..

The other downside is blocking airflow to the radiator. If you live in a hot state like AZ, I would consider a smaller one (height wise ) and add alcohol injection to help cool the intake temp charge.

decided to go with an intercooler thats 2.5'' shorter. the intercooler piping im looking at is .065" is that too thin?

.065" is not too thin.

But it can be a little more difficult to weld, especially in the outside of the bend areas where it has been stretched thinner.

Not really a big deal, just enough to require a little more attention.

There is little to no reason to run a core larger than 3.5" x 12" x 14" on anything 500whp or less, and no reason to go over 18" in length anything more than that is gaining you next to nothing but weight, and lag.

~S~

zero r. what do you think about a core that is 18x8x3. its long but shorter and thinner

Longer=more restriction/pressure drop. But better cooling
Less tubes=more restriction/pressure drop. And less cooling capacity.
Less tubes that are longer = more restriction/pressure drop x2 Clearly bigger is not always better for reasons already mentioned, but too small can become enough restriction to kill some power

^^ Well stated, it's good to keep in mind that about 80% of the cooling gets done within the first 20-30% of the core most times. Once you go over a certain length the trade off is not worth the effort in most cases. Same goes for thickness as well once you get past a certain thickness you're not gaining much in a drop of temperature. More or less more weight and more lag for very little return.


~S~