Quoting broxma:
So I'll address the initial argument about airflow across that core and the part about stagnant air in the core.
With the inlet at a 90 degree angle to the tank, the air will, because it flows like a liquid, hit the flat back of the tank(Front of car) and deflect at a 90 degree angle in all degrees. This means, some will run directly into the side of the tank and redirect again. Some will go down, some up and some right across the core. So three things. First, the 90 degree inlet has some value in that it naturally causes turbulence in the air which is actually part of what makes intercoolers work. If the flow were totally laminar, the efficiency would be garbage. Second, some of the air is very turbulent, especially the air that hits the back of the tank, then the side, then who the hell knows. Each time the air is redirected it is a net loss in engine power with a fairly well calculated constant for redirection at different angles, the 90 box tank design being pretty bad. Third, there would never be literally stagnant flow in the core. It may be woefully inefficient, but it would never stop.
Now the meat and potatoes. The exit. The 90 degree box end tank design is the absolute worst way to get the air out of the core. It requires all air to dramatically redirect to a single point, and remember, the air is being pushed under boost, not being sucked in by the downward travel of the piston. The exit design shown in the first picture would have a horrible effect on the efficiency of the over all system. So much so, I'd advise against it.
And onto further points of order. Why? I know I threw that question out originally Jeff but I meant it from a very serious perspective. From a position of total mutual respect, other than you already have the core, why do you want to go with that system design? It cannot be for throttle lag and if you say turbo lag, we will have had a breech in our bonds of mutual respect. If it is simply due to the current ownership of the core, I do have some advice though as I am not one to just point out problems without offering a solution. Find a shop that can weld aluminum. Cut the 90 degree outlet pipe off. Weld up that hole. Put the outlet on the far side pointing towards the passenger side of the car and run the pipe under and around. Several reasons. The outlet flow will be much improved. The majority of kits use a similar system making it typical\traditional. Tradition is not always a bad thing and often going against that grain shows no improvement and often negative returns(See: How do I make my GVR4 RWD). Many times, we stick with tradition, because it works. And finally, reducing the length of pipe even a large degree will have no effect on the performance aspect of the car.
I'm more than willing to discuss any ideas you have however. If the entire goal is simply to have the pipes within the interior of the frame rails, then your path is set. I abhor the 90 degree exit. The reduction in bends from a normal, straight out, under and around pipe design will be outweighed by that horrible exit design. If the end tank were rounded, all core exit points leading to a smooth transition out the core like on some upper end cast designs, I'd say go for it.
/brox
thanks for the insight.
I got the welding down, the second pic is the intercoolers current state, and the first pic was my first idea.
with the intercooler the way it is, it has to make the 90 the outlet of the intercooler. around here I have a bunch of issues with bottoming out the car, even on a stock ride height. I smashed my in/out pipes on my mirage almost flat. my short route, wasnt for the intention of gaining power, just for keeping it out of danger so to speak. but I dont want it to me so bad that a smaller intercooler that I could move easier actually flow better.
what if I made the pipes come out of the top of the intercooler, then make a 90?
do you believe that the outlet 90 is so bad that having it be a straight shot into the TB wont make up for it? right now, I know it has to be better than stock, but I just want to make the cooler I have work as good as possible.