I'm building a turbo setup on my car and I'm trying to figure out an intercooler solution. The space in front of the car limits intercooler core sizing and piping options. I am expecting a maximum of around 275 HP and 275 lbs-ft at the engine. I want air-air IC for simplicity and cost reasons.
I see a lot of intercoolers on eBay. I used those before with success, but somehow they all seem too wide, too long, too thick. I have read Corky Bell's book and I know that it's better to have a short intercooler with a large core section area than a long intercooler with less core section area.
I found out that the Nissan GT-R uses two smaller intercoolers, which look to be about 12" x 10" x 3". I can't find the measurements online. Those come quite cheap from recyclers. The Nissan has 565 HP stock. Owners seem to be having good success with the stock units even at higher power levels (let's say 650 HP). I figure that if the Nissan has 565 HP and uses two of those units, one of them should be good for 282.5 HP, meeting the requirements of my project. But, if I go by the formulas and charts in Corky Bell's Maximum Boost, I would need a core section of 16" x 3" to cool 275 HP adequately. It seems like either the theory is too conservative, or somehow my reasoning doesn't make sense. I noticed that a lot of people building turbo cars seem to have huge intercoolers for the power they are running, OR getting away with long cores with limited core section area... What do you think?
The intercooler in question: