How do I buy the proper intercooler?

MustangChris · Aug 23, 2009

Hello all,

Im starting to keep my eyes peeled for parts for my build, now that I'm starting finally. lol.

How do I purchase a proper intercooler? (this might be a good sticky thread.)

I'm NEVER going to run under 17 PSI and NEVER over 26 on a top mount.

The salesman at Kenne Bell said to use an OEM 2003/2004 cobra one. After I asked him if this would be a "restriction," he said the following:

"Yes you can run the stock lower and stock I/C at any boost the compressor can produce. Is it a restriction? Possibly, but I don't know of anyone who makes an intercooler core for those vehicles. You can get a larger heat exchanger for the front of the car but the core is probably as good as it gets unless you make your own core. " - TJ Sico ~ Kenne Bell Tech Support ~ 8-19-2009.

I understand that intercoolers come in a variety of shapes, sizes, and depths. How do I know which one is right for me?

Do they come in different matierials? are some materials better than others? will painting it or powder coating harm performance?

What are my options?

Thanks all,
Chris

blown98gt · Aug 24, 2009

first off there are different types a/a a/l so you have to decide on that. the procharger 3 core a/a is a great intercooler imho and i've had great success with it at 20lb of boost on a daily driven car.

you are defiantly going to want at least a 2/3 core i'd say go 3 core and as far as a/l is probably the best route for you also. the only reason i've not had any issues with a/a is because i'm also running meth injection. if you are running a kb you might want to look into like 03 cobra i/c upgrades because most of them are good upgrades for the kb

MustangChris · Aug 24, 2009

Okay. What are the benefits to a/l vs. a/a?

Is the OEM Cobra a 3 core? or 2 core? Is it a/l or a/a?

Daily driven I will probably be running 18 PSI. and 25 at the track. (yes i realize this will take a pulley and belt swap at the track)

Thanks for your help

Also, will powder coating or painting it cause performance issues? or are there certain materials that work better than others, (aluminum instead of steal?)

blown98gt · Aug 24, 2009

if i were you i'd defiantly look into getting a meth injection for boosting that high, also aluminum is always cooler from what i've seen than steal. powder coating it shouldn't cause any performance issues but i've not done it. nor have i seen or met anyone who has done that. i believe the OEM cobra is a 1-2 core. I didn't even know the KB would see 25psi even on their mammoth kit. You will "HAVE" to run an 8 rib setup. there is no question to it, there is no way you'll hit 25psi on a 6 rib and there is no way you can hit 25psi with no belt slippage. So go ahead and plan on swapping over to an 8 rib pulley setup. You'll gain a few psi on the swap alone but doing it on the d1sc was the best thing i've done 0 belt slippage at 20-22lbs of boost.
Look into a RR 8 Rib pulley because they make 8 rib pulleys for KB, prochargers, and so on. also look into a BGG 8 rib kit.

i know i was pretty vague and didn't answer all your questions but a/a is just air going through the intercooler (small layers of stuff that cools the air lol) and a/l exactly how it sounds, air is cooled with liquid when it passes through the intercooler

97stanger · Aug 24, 2009

I run a Paxton front mount. zero problems great fitment!

blown98gt · Aug 24, 2009

he's running a kb not a paxton, vortech or procharger... kb is different in the twin screw vs centri. if it was me the procharger 3 core fits great has been on 1000 hp applications and is a great intercooler.

MustangChris · Aug 25, 2009

i think ill get an aluminum, a/l, 3 core, black intercooler.

as for the 8 rib belt, already budgeted that into the build

gunna be on my list.

the KB 2.8 mamouth is so far the only top mount for the 03 that runs to 26 PSI. (according to kenne bell) the salesman said they were working with a whipple and it blew up at 26, so thats where they stopped testing the KB. lol. i plan to run 25 MAX, 18,000 RPMs MAX, and 17 PSI min.

Thanks for your help all!

feel free to add any additional information incase this thread gets a sticky note.

justinschmidt1 · Aug 25, 2009

Uh, do you have a 03 cobra that I dont know about?

MustangChris · Aug 25, 2009

justinschmidt1 said:
Uh, do you have a 03 cobra that I dont know about?

lol, no. I have a Teskid 4 bolt aluminum block thats getting 03 cobra heads and 2.8 KB.

(check out my build thread :-D lol)

will there be problems fitting an 03 intercooler in the front opposed to an aftermarket one?

justinschmidt1 · Aug 25, 2009

I gots no idea

blown98gt · Aug 26, 2009

no you shouldn't have any issues

330CubeGt · Aug 26, 2009

Im running stock boost right 8-10 psi now :dontknow: but i have a 03/04 cobra Heat Extractor and a Moroso Supercharger tank/ Ice box.
The Lightning unit is almost identical but is taller and i wish i had known when i bought this one because stock for stock the lightning one is much better.
If you can get a Dual Pass extractor,That way the water has more time to cool.

the Moroso tank i run is about the size of a battery but i have been thinking of a 2-3 Gal tank in the trunk to stuff with ice so thats always a option for you.

Here is a link for a 03-04 LFP Extreme Dual Pass Intercooler

http://www.lightningforceperformance.com/index.php?main_page=product_info&cPath=234_129&products_id=319