Thanks Jody, it's still a work in progress... I'm doing all the work myself so it's taking much longer than farming it out (TO THE PROFESSIONALS
)... I have, what I think is a pretty trick set-up for the intercooler / heat exchanger and plumbing... I've ported and polished the intake and outlet of the OEM Garrett charge air cooler and acid washed the core to get all the manufacturing debris out from between the fins ( A BUNCH OF IT)... "MADE IN MEXICO" remember ? I also bored the OEM 5/8" inlet / outlet to 3/4" and fitted them with new brass fittings.
Also, when I disassembled the engine, I noticed there is a good 3/4" gap between the charge air cooler and the V in the upper portion of the block, so I am making a insulation blanket that will fit into this gap. (
http://www.thermotec.com/) and absorb some of the radiated heat from the engine.
I have also hired Gerharf Schruf (Bell Intercoolers) to make a custom heat exchanger that is 3.5" D X 6.5" H X 18" W with 3/4" pipe barb that will fit nicely in front of the radiator ($389). This will be fed by the Johnson Marine Impeller Pump #10-24540-03 that is rated at 6.9 gal per min. and has 3/4" pipe barbs at both ends ($169).
Now the plumbing took me a bit of thought, especially after studying the way the OEM was set-up and how prone it is to HEAT SOAK... The OEM intercooler pipes are these puny aluminum, un-insulated tubes and the shared coolant tank is rediculous for serious HP. So, I am having custom 3/4" "heat sink" tube made by Cain Industries (
http://www.cainind.com/) that will reduce coolant temperatures by a factor of 12:1 (2- 6' sections $380)
Then, for the coolant tank... Skeets Holland is making a custom 1.5 gal. coolant tank with baffled slots to insert four 2" X 6" X 6" blocks of dry ice. The entire cooling system will use alcohol and propylene glycol. ($450) I have not decided where to place the tank yet, but under the hood is definately not the location of choice !!! Your idea is more likely, however, that is where the MOTEC is going, so that is a consideration...
Wait until you see my version of the full race CAI for this thing... It won't even run through the engine bay...