About two weeks after my initial sketch, I had the final product from Bell Intercoolers in my hands. It was fabricated in San Antonio, Texas, so being made in the USA cut down on shipping. I could have had it even faster if I paid for quicker shipping, but there is no rush and I need to save money where I can. The intercooler came very securely packed to prevent shipping damage. The intercooler was sealed in a bag and all the hose connections had red caps to prevent anything from getting into the intercooler. Notice the water end tanks have a depth of 1.5” to allow for good water distribution across the core.
Looking inside the air inlet side of the intercooler, you can see the air guide to help get more equal flow distribution across the core for better effectiveness. This side has the 2” inlet, so the end-tank has a slight taper. You can see how the air will have expand just a little bit going into the end tank.
On the outlet side with the 2.5” hose connection, the airflow has to make a minimal step. An important characteristic of the air-to-water core is the difference in flow path heights for the water flow and the air flow. We couldn’t get a good picture through the small ¾” hose barb for the coolant, but if you look inside, can you see the coolant flow paths through the core are smaller. Coolant having much higher heat capacity than air requires much lower flowrate. So, in an air-to-water core, the flow path width is biased to be greater for the airflow which also reduces the airflow pressure drop. We definitely like minimal airflow pressure drop.
I measured the front bumper opening at roughly 27” wide and 6” tall. In the middle is the receiver/dryer for the air conditioning system.
The distance from the receiver/dryer to the back of the black plastic grill is about 2”.