best / most efficient intercoolers? How to tell?

[myke_w]

Can we get a list of the best / most efficient inter coolers going? I'd be interested in air - air and air - water applications.

Also any information that helps to determine efficiency would be useful..

[xud9te]

Well, you would have to test each 'cooler in the specific application (or one application for all tests) to achieve a satisfactory comparison.  

Basically if a 'cooler is over 80% efficient and has less than a 8% pressure drop accross it, then its a good one for the application (discounting charge volume - i.e. as long as its not too big).

Testing for temp is simple.  Insert a k-type thermocouple before and after the IC and record the temp drop.  

Testing for pressure needs a boost guage connected before and after the IC.  Without making an adapter that fits in the IC hoses with a fitting for a pressure reading, the compressor output and any manifold pressure connection (LDA?) can be used, but his will also record pressure drop in the intake piping.

[myke_w]

is there a particular range of inter coolers that are best when used in our applications? I have a massive Volvo inter cooler, but it seems like that would cause way too much lag, I also have a smic from a tdi and it' seems pretty small, maybe too small to make any difference..

[jtanguay]

is there a particular range of inter coolers that are best when used in our applications? I have a massive Volvo inter cooler, but it seems like that would cause way too much lag, I also have a smic from a tdi and it' seems pretty small, maybe too small to make any difference..

a small intercooler can be great on our cars.  the only issue is getting enough airflow to take the heat away.  you can use a fan, a hood scoop, or some even use misting systems to help dissipate heat.

if you can fit the volvo intercooler, i think the cooling capacity will offset the increase in turbo lag.  one thing that will most definitely increase turbo lag, is a set of really badly placed intercooler pipes and some sharp bends.

[nogama3]

i have an intercooler fitted to my aaz golf mk3 where it appears that it does not get much cooling :

i made a recent beach trip (150 miles) and when i got there i checked the temp of the pipes to and from the intercooler:

and the one from the turbo to the intercooler was very hot and the one from the intercooler into the inlet manifold was slightly warm and i was surprised on how effective the intercooler was.
i have managed to purchase a front mount intercooler from a sharan i beleive:

which should fit into the front bumper and should help cooling the air further.