I agree that the end tank design has to be done correctly.... its about flow...
coming from a 2.5x8.5in core from stock or only 21.25 square inches of flow area and that's not even that because the tube/fin design has smaller channels than the bar/plate design... every High HP car has efficient cooling for bigger turbos... if I recall correctly, Todd @ protomotive is all about the flow.... he redesigns the intake system... he won the 2004 april shoot out... basically blew everyone out of the water.... literally...
and I know he uses bigger I/Cs

 

will there be any drop on the air flow due to the larger 4in intercoolers?

 

barebones,

The air flow can become a problem (friction ... especially at low flow circumstances. This is why fans are employed with certain thickness) however there is a larger problem. The real problem occurs due to the fact as the outside air passes thru the core it is absorbing heat. At a certain point the air passing thru the cooler is of no use or worse yet adds heat to the final rows.

 

Todd Knighten's intakes do not draw air from the stock intake box. He installs conical filters in the fender cavity which provides a very short route to the turbo. Little to no friction on the up side, alot of cabin noise on the downside. This has nothing to due with the IC as the IC is on the pressure side of the turbo, not the feed side.

I'm saying more than I should. I wish you all the best with this mod. bye.

 

Chad is correct, the intake system is completely re-designed with a much more efficient route to the turbos.

As for the ICs on my old car, they were custom built by Protomotive and worked very well. In fact, they even mounted in the stock location behind the bumper! Todd claimed 98% efficiency, which is quite impressive!

Makes me wonder if I might need those intercoolers again. I wonder what the efficiency on the Secan intercoolers are, and what makes them $20,000... cool stuff and race proven, but what is the secret ingredient?

 

Tyson, yes TK makes some very efficient IC's. You really can't get anymore efficient. I didn't realize Todd's were efficient to that degree. Just goes to prove what I know.

 

Thats why Todd asked me to shoot him a pair if these cores cause he really liked the dimensions

 

The intercooler subject is one that is fundamental to anyone looking for serious HP. Those cores and end tanks built for Markski are certainly very nice.

I tend to agree more with CJV on what he said about width and size. The art is in getting the right sized intercooler for your turbos, boost pressures and state of tune, wider is not "always " better and viceversa. The only way to find out is thourhg a lot of datalogging and testing under the conditions under which the engine will be used.

On my engine dyno datalogs from Todd K. I can see very high intercooler efficiency (>85%), what I don't know is whether this efficiency will be sustained on the road at 1.2 Bar. The bar and plate I/Cs are the way to go as evidenced by the Secan cores and Todd's.
The Secan intercoolers are more like $30K not $20K and the price is there for a reason, the build process and materials used are not your everyday $5k intercooler. The US Spearco, Griffin and Bell cores are good it seems, but anyone thinking they are as good as the Secan is wrong.

If you look well at the picture that Craig posted, the 996 Secan cores are not thick. The same applies to the 993GT2 EVO Secan I/C, they are thin. See the picture below of the white 993GT2 EVO. The cores are rather thin (same thickness as my 993TT Protomotive core) but much bigger, they fill the entire engine bay. Those Thick Cargraphic intercoolers have been tested by RS Tuning to be less efficient than stock. A thick intercooler might be more helpful for a street car seeing stop and go rather than large airflow during a race, however there are limits beyond which pressure drops too much.
Below are some pictures of my Protomotive intercooler.
Just as an aside, RS Tuning (not entering a Euro-US debate here can we?) goes for Secan in their 642BHP 996TT engines, and they maintain that nothing else will do for sustained power, proof was the Alzen car with boost lowered to 1.1 Bar and it had the Secan.

 

Here are the Cargraphic sold, RS tuning IC's. Around $15,000 for these puppies. Made by Secan perhaps?
http://www.cargraphic.com/index.php?...,1057/&start=3

 

Are these short intakes and conical filters on a 996 tt or 993 tt?

 

These are on the 996tt. It's nothing new abeit rare. That was the way Tyson's tt was set up years ago. Yes, they use a conical filter.

 

We also use this set up when we go to 600hp.

Neil

 

OK - I am gonna do this. Where do I get some info. on what works?

 

GROUP BUY! I wonder what kind of price we would get on a decent volume purchase?

 

they r made as one offs probably..... its far more cheaper to do what I did....