Technical => Engine Tech => Topic started by: Nate on November 16, 2005, 08:30:53 PM
Title: intercooler for KB blower
Post by: Nate on November 16, 2005, 08:30:53 PM
anybody have a kenne bell blower know if this would work? if i end up getting one, i would like to be able to have an IC for it... and sence they refuse to make one, i might end up haveing to. just got to think'n today...
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 08:36:21 PM
Did you read their FAQs?
Quote
Why doesn't Kenne Bell offer intercoolers? We do. Kenne Bell has been selling our own air to air intercoolers for the Buick GN for 13 years - and the Syclone/Typhoon for 10 years - well before the supercharger industry even considered intercooling. If intercooling was the way to go with our Twin Screw Supercharger, we would be using one. There are 2 ways to approach supercharging: 1. use a supercharger and/or boost that won't work without intercooling or 2. design kits with a supercharger that is efficient enough that it doesn't require an intercooler. Kenne Bell has chosen the later. First of all, contrary to popular belief, intercoolers do not "make" more horsepower. They cannot. Supercharger output is FIXED and doesn't increase merely because downstream air charge temperature is lowered. It's the same air by mass. The mass, the weight, the oxygen content of that blast of air discharged by the supercharger cannot be increased. You don't believe it? Try this. Capture the discharged air in a bottle, seal it and weigh it at 300°, 200°, -50°. The weight (mass) won't change, the engine can't ingest more air so it won't make more power. Yes, the cooler denser air, at -50° for example, will "allow" more boost or advanced engine timing but that air, by itself, won't make more power. Now if the air entering the supercharger (ambient) is reduced, it is denser and cooler and then will make more power (1% increase for every 10° temperature drop according to our data). So why intercool? If the supercharger is relatively inefficient with a high discharge temp and the engine knocks at 6 psi, then the air charge temp must be reduced. Retarding ignition timing or lowering the boost to 4 psi reduces power, so that is not an option. Fortunately, the Kenne Bell Twin Screw is the most efficient supercharger concept available being around 60° cooler than the competition at 6 psi, so an intercooler is not needed to remove an extra 60° from the air charge.
If I ever found myself able to afford one of their blowers, I'd probably use that (on top of a GT40 lower intake) plus one of their Ram Air kits.
Title: intercooler for KB blower
Post by: Nate on November 16, 2005, 08:58:06 PM
but that dosnt count for the blowzilla does it? i mean, after a cirtain point that air is going to get real hot, and haveing 12+ psi will cause problems wount it? why else would some of the guys running more hopped up setups have to run water injection or alachol injection which i hate.
Title: intercooler for KB blower
Post by: SLEEPER T-BIRD 87 on November 16, 2005, 09:17:53 PM
kenne bell makes some of the worst 5.0L blowers for power production . Look into the ati Procharger. about the same range and a whole lot easier to use an intercooler.
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 09:18:24 PM
I would think you'd have to ask them that. It was never my intention to run more than 6-8 PSI, if I got one of those.
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 09:20:08 PM
Quote from: SLEEPER T-BIRD 87
kenne bell makes some of the worst 5.0L blowers for power production . Look into the ati Procharger. about the same range and a whole lot easier to use an intercooler.
But he didn't ask about ATI Prochargers, now did he?
Title: intercooler for KB blower
Post by: SLEEPER T-BIRD 87 on November 16, 2005, 09:28:33 PM
Quote from: Bird351
But he didn't ask about ATI Prochargers, now did he?
I just stated an opinion if you dont like it dont respond to my post
I was just was saying in the long run it may be cheaper.as the kenne bell is expensive and the ati offers one with a intercooler kit also for about the same cost.
And to add to this anything can be done if you use you imagination.
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 09:40:10 PM
If you can't handle a little criticism, I suggest you not post in the first place. If you make a public post, you had better be prepared for public response.. good AND bad. Welcome to the Internet.
It's one of my pet peeves around here that people don't even bother to address the topic, they just say "it sucks, buy/do this instead".. well what if he, like me, does not want a ed centrifugal supercharger? Then you've given him useless "advice". (more like opinion passed off as advice.. and you know what they say about opinions) At least attempt to open a dialog on what to do with the KB, before pushing off your opinion as advice. Some of the other readers here, like myself, (only interested in a KB supercharger, if I get any supercharger at all) might be watching this and hoping for decent feedback.. so you're not only screwing the original poster, you're screwing anyone else who might get use out of this as well.
Yeah, maybe it's unfair I'm taking out my rotten mood on you by calling you out on this.. but deal with it. I'm dealing with far worse than being called out on a bad post, right now.. you can deal with a little criticism.
Title: intercooler for KB blower
Post by: SLEEPER T-BIRD 87 on November 16, 2005, 09:50:59 PM
Quote from: Bird351
If you can't handle a little criticism, I suggest you not post in the first place. If you make a public post, you had better be prepared for public response.. good AND bad. Welcome to the Internet.
It's one of my pet peeves around here that people don't even bother to address the topic, .
I did adress the first post. so quit mucking this mans thread up .
Quote from: Bird351
Yeah, maybe it's unfair I'm taking out my rotten mood on you by calling you out on this.. but deal with it. I'm dealing with far worse than being called out on a bad post, right now.. you can deal with a little criticism.
I really do not care about your problem like i said dont like it keep your mouth shut.Period. if you got a problem please feel free to send me a p/m and i will help you adress it in private.
Title: intercooler for KB blower
Post by: Nate on November 16, 2005, 10:17:01 PM
ok, so....
sleeper, im interested in the twin screw setup for its clean apearance, and its simple ducting. those centrifugal blowers just seem too inefficiant and have alot in the way. besides, i'd have to put money into a higher flowing upper intake where as the twin screw is the upper intake. but thats just my opinion.
and besides, i dont even know if what i posted above is possible. i know somebody hear has a kb setup... i just want to know if what iv seen in all the photos is true, and if i ever do get to a higher boost application, i would like to be able to modify it for a intercooler. i plan on running it for a while wthout one, possibly selling it and buying a bigger one when i go to a 408 down the line... maybe in 3 years or so. anyhoo... its all hypathetical so try not to kill each other over a stupid question. :D
Title: intercooler for KB blower
Post by: SLEEPER T-BIRD 87 on November 16, 2005, 10:24:40 PM
Quote from: Manson
ok, so....
sleeper, im interested in the twin screw setup for its clean apearance, and its simple ducting. those centrifugal blowers just seem too inefficiant and have alot in the way. besides, i'd have to put money into a higher flowing upper intake where as the twin screw is the upper intake. but thats just my opinion.
and besides, i dont even know if what i posted above is possible. i know somebody hear has a kb setup... i just want to know if what iv seen in all the photos is true, and if i ever do get to a higher boost application, i would like to be able to modify it for a intercooler. i plan on running it for a while wthout one, possibly selling it and buying a bigger one when i go to a 408 down the line... maybe in 3 years or so. anyhoo... its all hypathetical so try not to kill each other over a stupid question. :D
ok man.
What lower intake will you be using you could probly fab a elbow kind or what is used on the powerstroke diesels. Just an idea good luck on your project.
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 10:26:11 PM
You know what? **** you, Asleep at the wheel. Welcome to my ignore list, asshole.
Title: intercooler for KB blower
Post by: Nate on November 16, 2005, 10:30:59 PM
well if i do this, i'll be useing my gt40 intakes lower. so its gonna be ported out and puddle welded. then probley go and port out the kb air exit manifold and then i dont know, fab up some duct work, and yes lol, i was thinking of that elbo like the diesels have, except i got the idea from the fulie 460 intakes. if only i were rich lol, id be playing around with it rite now. maybe i can patent the idea and make the money back for the blower lol.
Quote from: SLEEPER T-BIRD 87
ok man.
What lower intake will you be using you could probly fab a elbow kind or what is used on the powerstroke diesels. Just an idea good luck on your project.
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 10:31:49 PM
Quote from: Manson
ok, so....
sleeper, im interested in the twin screw setup for its clean apearance, and its simple ducting. those centrifugal blowers just seem too inefficiant and have alot in the way. besides, i'd have to put money into a higher flowing upper intake where as the twin screw is the upper intake. but thats just my opinion.
and besides, i dont even know if what i posted above is possible. i know somebody hear has a kb setup... i just want to know if what iv seen in all the photos is true, and if i ever do get to a higher boost application, i would like to be able to modify it for a intercooler. i plan on running it for a while wthout one, possibly selling it and buying a bigger one when i go to a 408 down the line... maybe in 3 years or so. anyhoo... its all hypathetical so try not to kill each other over a stupid question. :D
It doesn't look like it's possible, just looking at the bolts holding that part on.. the part you want to switch. The upper (in your pic) bolts are in a line, and the lower bolts are in a ^ pattern. However, I'm sure pretty much anything's possible with enough tinkering. If you did manage to make it work, I'd be interested in how tough it was.. and how much of a difference it made after the effort. They may say an intercooler isn't necessary, but why not try if you think it's worth the effort?
Sorry for the rest.. but I'm in no mood to put up with this guy's shiznit. Frankly, if he had mouthed off to me in person in the mood I'm in right now, I'd have outright shot him.. I'm in that bad of a mood.
Title: intercooler for KB blower
Post by: SLEEPER T-BIRD 87 on November 16, 2005, 10:39:46 PM
Quote from: Manson
well if i do this, i'll be useing my gt40 intakes lower. so its gonna be ported out and puddle welded. then probley go and port out the kb air exit manifold and then i dont know, fab up some duct work, and yes lol, i was thinking of that elbo like the diesels have, except i got the idea from the fulie 460 intakes. if only i were rich lol, id be playing around with it rite now. maybe i can patent the idea and make the money back for the blower lol.
yeah, It will probly take a ton of fabrication but should be worth it in the end.
Title: intercooler for KB blower
Post by: SLEEPER T-BIRD 87 on November 16, 2005, 10:44:22 PM
Quote from: Bird351
You know what? **** you, Asleep at the wheel. Welcome to my ignore list, asshole.
Sorry to the thread starter but I will not let some one cuss me and act childish at my exspense
I will adress both you post's right here. I told you if you have a problem you need to p/m me . if you want to threaten to shoot me come on big boy I am not scared of you. These post of yours are being forwarded to my attorney. You are the one with the mouth on you so please keep it to yourself.I am reporting these post also.
Have a nice night Bird351
Title: intercooler for KB blower
Post by: Nate on November 16, 2005, 10:46:37 PM
i dont doubt all the fabb'n lol. i just dont want to resort to water injection if i EVER get to that point. and bird, i see what your talking about. its probley a better idea to just make an aluminum wedge to replace that part and attach the duct to that instead of flipping it.
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 10:52:17 PM
Could you cut the exhaust piece off one side of that fitting, cut off the right side of the fitting, and swap the two? Sounds like a pain in the ass..
I still say KB are the people to talk to next.. if you really want to do an intercooled application with their hardware, I'm sure they'd at least talk to you about it. I had planned on talking to them about the boosted I6 project when the time came, just to see what they had to say.
Title: intercooler for KB blower
Post by: Nate on November 16, 2005, 10:55:32 PM
that might work to, im not sure how kb would react, or if they would answer any questions. i'v heard their costomer support sucks. iv also heard that people talking to them about intercoolers just get shut down lol. probley because they designed the blower specificaly not to use one lol.
Title: intercooler for KB blower
Post by: shame302 on November 16, 2005, 10:55:51 PM
the 03 cobras use basically what your looking for. now the eaton isnt nearly as efficient as the kennbell but i "think" that guys that run the kennbell on 03s still run the cobras cooler. im not saying in anyway that that one would work but im sure it would help build more power.
is it nesessary...no, would it help, i bet it would. would it be unique...shiznit yeah. i wouldnt doubt something could be fabbed up as basically some sort of flow through spacer under that bad boy. all i could say is it couldnt hurt too mess around with it if you have the fabbing/machining skills, equipment and time...of course...ya gotta ask yourself what kind of power you are looking for.
id realy have to physically have one in my hands to realy give any input on how id build something. personally, from the pic and thinking of a gt40 lower...id start with a few hunks of aluminum and a bridgeport. does the KB use some sort of lower plenum to mount to a ford lower intake or more likely directly to the heads? i realy need to see how they are installed on a 5.0. makes me feel ignorant...i should know this.
i myself never cared for them but now im focused on using that setup on my DOHC cause of the torque they make...
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 11:00:31 PM
Quote from: Manson
that might work to, im not sure how kb would react, or if they would answer any questions. i'v heard their costomer support sucks. iv also heard that people talking to them about intercoolers just get shut down lol. probley because they designed the blower specificaly not to use one lol.
Well in that case.. if they did in your lap over questions about their stuff, then they wouldn't deserve your business. Their goal should be to get you to buy a KB supercharger for your application, and reasonably accomodate you if you want to do something non-standard. If they can't or won't do that, then piss on 'em. But you never know until you try to talk to them.
I'm hoping you do get somewhere on this if you decide to try it.
Title: intercooler for KB blower
Post by: slamedcat on November 16, 2005, 11:17:56 PM
Don't know if you have thought about this but there is an intercooler out there for the M90 on the GTPs, please don't shoot me for this.
Basicaly it mounts between the Supercharger and the lower intake. It looks and acks like a radiator. Two hoses and a small pump. You have a remote mount tank for your coolant of choice. Then the pump pushes the fluid throught the intercooler and back to the tank to cool down.
You may be able to make somthing like this.
Title: intercooler for KB blower
Post by: shame302 on November 16, 2005, 11:23:31 PM
cool...i looked at a KB on a 5.0...looks like it bolts right to the lower so im confident something could be made up without too much trouble. thats the kind of stuff that makes me wish i had access to a machine shop...
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 11:25:19 PM
I wouldn't shoot you. :p I wouldn't normally shoot this guy either.. unless in the hypothetical situation of him mouthing off to me in person the way he has here so far in this thread, with me in the mood I'm in right now. He's probably taking it as some sort of threat to his manhood or something, though..
Title: intercooler for KB blower
Post by: slamedcat on November 16, 2005, 11:27:54 PM
No, I ment about the suggestion of using *GASP* a chevy part on our cars. But ya nice to know I'm not on the ignore list yet.
Title: intercooler for KB blower
Post by: Nate on November 16, 2005, 11:32:26 PM
yeah i saw that. thats origionaly what i was thinking of, but then i noticed how its ducted. dunno tho... i guess i'll actualy have to get a hold of one in order to experiment. not like i dont have any time to think about it lol.
Quote from: slamedcat
Don't know if you have thought about this but there is an intercooler out there for the M90 on the GTPs, please don't shoot me for this.
Basicaly it mounts between the Supercharger and the lower intake. It looks and acks like a radiator. Two hoses and a small pump. You have a remote mount tank for your coolant of choice. Then the pump pushes the fluid throught the intercooler and back to the tank to cool down.
You may be able to make somthing like this.
Title: intercooler for KB blower
Post by: Bird351 on November 16, 2005, 11:41:31 PM
Quote from: slamedcat
No, I ment about the suggestion of using *GASP* a chevy part on our cars. But ya nice to know I'm not on the ignore list yet.
Of course you aren't. He's the only one, in fact. All other past issues have been dealt with, with the few people who have been on there before.
Believe it or not, I like most of you people here. If I didn't, I would not have made such a big deal over the fundraising thing awhile back. Even the people I don't "like", I don't really have a problem with most of the time. I'm just indifferent to 'em. As you can guess, I could do much MUCH worse than "indifferent". :p
Title: intercooler for KB blower
Post by: Bird351 on November 17, 2005, 12:19:35 AM
BTW, to whomever gave me the negative rep with the comment:
Quote
making smart comments not thinking of other on the board
It was exactly others who I was thinking of when I made the comment.. along with myself. I am someone who is interested in KB superchargers.. and as is obvious with Manson's posts, I am not the only one. I am sure we are not the only two interested in KB superchargers or in possibly using intercoolers (aftercoolers?) with them. So your reputation response was petty and ill-informed. But please.. keep those negative rep responses coming. My rep should not be as high as it is.
Title: intercooler for KB blower
Post by: Ifixyawata on November 17, 2005, 12:59:08 AM
:locked: :locked: :locked: ??
I sure hopes not. Ahyuk.
Title: intercooler for KB blower
Post by: Bird351 on November 17, 2005, 01:02:33 AM
Why lock it, Brian? Manson has a valid question.. and aside from the other shiznit, which I addressed by putting the one guy on ignore and laughing at the other guy who repped me, it's a topic we can pursue without too much .
EDIT: More silliness..
EDIT #2: You do NOT have my permission to pass along my ICQ # (if you have it) to people who are ignored on this forum, who wish to continue arguments after they've been dealt with. I consider that private information.
Title: intercooler for KB blower
Post by: SLEEPER T-BIRD 87 on November 17, 2005, 02:43:32 AM
Quote from: Bird351
Why lock it, Brian? Manson has a valid question.. and aside from the other shiznit, which I addressed by putting the one guy on ignore and laughing at the other guy who repped me, it's a topic we can pursue without too much .
EDIT: More silliness..
EDIT #2: You do NOT have my permission to pass along my ICQ # (if you have it) to people who are ignored on this forum, who wish to continue arguments after they've been dealt with. I consider that private information.
Why are you messing up this mans thread? With this foolishness between you and someone else?Take it to p/m's keep the topic on track. :locked:
Title: intercooler for KB blower
Post by: V8Demon on November 17, 2005, 06:48:34 AM
Anyway, the Kenne Bell setup and others like it (roots and twin screws blowers) are not designed for peak power. They are designed to start making boost very early in the RPM range. Here's some good info on that: http://www.superchargersonline.com/content.asp?ID=76
You can crank up the boost on anything with a pulley change, though.....As far as an intercooler you may not have to do all of the fab work. You could always do some shopping for an 03/04 Mustang Cobra intercooler and figure out how to mount it. Those intercoolers are up for sale all the time cause guys go bigger with their setups.
Title: intercooler for KB blower
Post by: Thunder Chicken on November 17, 2005, 08:52:11 AM
Take the fight to PM guys. I'm not gonna lock this thread because it actually does contain some useful information, but if the foolishness continues it's gonna have to go
Title: intercooler for KB blower
Post by: shame302 on November 17, 2005, 09:49:01 PM
Quote
You could always do some shopping for an 03/04 Mustang Cobra intercooler and figure out how to mount it.
eek...id think there are too many differances. i havnt looked directly at one but the cooler for the 4.6 cobra replaces a lower intake altogether "i think". the eaton bolts to that. the 5.0 KB bolts on like an upper intake. im sure there are way too many differanced between the windsor 5.0 and the mod 4.6.
i couldnt see why you couldnt take a block of aluminum, bore holes through it where the gt40 lowers holes are, port match the top and bottom of the holes for the KB and the gt40 lower and then cut the bar in half horizontily. then mill out a water passage around the holes somehow, either in the passenger side, around the back and out the driverside front, or possibly flow right through it somehow and then mirror the milling in the other half. maybe cut cooling fins on the sides. a few fittings and some sort of gasket gor the halves, some hardware and you could have yourself a prototype right there....or a trainwreck...wich ever....lol
wish i could discribe it better but i suck...:rollin:
Title: intercooler for KB blower
Post by: V8Demon on November 18, 2005, 12:14:40 AM
Quote
cooler for the 4.6 cobra replaces a lower intake altogether
Nope the intercooler is mounted up front in stock 03/04 Cobra applications. Sounds like your referring to the intercaooler Kenne Bell makes for the superchargers THEY make for the 4.6. I meant the stock piece for Ford's eaton supercharger. Something like this...... http://www.southfloridapulleyhq.com/SFPH/cobra/ec_iche.htm
The idea you describe reminds me of the EGR spacer on a 5.0
Title: intercooler for KB blower
Post by: shame302 on November 18, 2005, 01:17:04 AM
no no.... i understand the actual cooler itself...the heat exchanger. what im talking about is the "lower intake" that the blower is actually bolted onto.....
Quote
The idea you describe reminds me of the EGR spacer on a 5.0
thats sort of what i was getting at yeah...to maybe help cool the air somewhat passing between the blower and the heads. im pretty sure thats how the factory unit works.....if course...i could be wrong.
note the cooler fluid lines going in and out of the "lower intake". it looks to be the same lower as the factory unit..
Title: intercooler for KB blower
Post by: RTStabler51 on November 18, 2005, 08:40:47 AM
Quote from: SLEEPER T-BIRD 87
kenne bell makes some of the worst 5.0L blowers for power production . Look into the ati Procharger. about the same range and a whole lot easier to use an intercooler.
If your looking for pure power, most people in the FI world know not to go the roots/twin screw type route. However, roots/twin screw give you what most people want on the street, instant power/torque. Period. If all you are looking for is peak numbers, sure a centrifugal is the way to go. If you are looking a kick in the fuggin pants down low, and roots/twin screw is the way to go.....
Title: intercooler for KB blower
Post by: RTStabler51 on November 18, 2005, 08:42:31 AM
Quote from: Paul Flockhart
Nope the intercooler is mounted up front in stock 03/04 Cobra applications. Sounds like your referring to the intercaooler Kenne Bell makes for the superchargers THEY make for the 4.6. I meant the stock piece for Ford's eaton supercharger. Something like this...... http://www.southfloridapulleyhq.com/SFPH/cobra/ec_iche.htm
The idea you describe reminds me of the EGR spacer on a 5.0
The actual intercooler on the DOHC 4.6 Cobra motor and the 5.4L SC Lightning motor sits UNDER the supercharger/between the heads. The heat exchanger is what is mounted in the bumper. We have water-air intercoolers.
Title: intercooler for KB blower
Post by: V8Demon on November 18, 2005, 08:56:08 AM
Ahh OK. It was explained to me a while ago and I misunderstood thinking that they were air to air. I guess Shame's idea in conjuction with the heat exchanger would be a good way to go.
Title: intercooler for KB blower
Post by: Thunder Chicken on November 18, 2005, 12:45:02 PM
You can get away with putting the intercooler in the "V" on a Modular engine because it's a very deep "V". The Windsor engines have a camshaft and lifters in that V, so there ain't much room there...
Title: intercooler for KB blower
Post by: V8Demon on November 18, 2005, 01:26:03 PM
The mental picture I have is somewhat of a spacer inbetween the lower and the Kenne Bell unit with a heat exchanger up front.... My question is how would you get continuous fluid flow? You need some kind of pump that can move liquid.
Title: intercooler for KB blower
Post by: RTStabler51 on November 18, 2005, 01:52:03 PM
Paul, we (Gen II L & 03/04 Cobras) have a seperate coolant system for the IC, which is moved via an electric pump. I can't remember if the pump is on all the time, or only at a certain temp....I want to say all the time...
Title: intercooler for KB blower
Post by: V8Demon on November 18, 2005, 02:05:10 PM
Does pump speed vary with engine speed as a water pump would or is it constant?
Title: intercooler for KB blower
Post by: RTStabler51 on November 18, 2005, 02:27:42 PM
I'm guessing, but I believe its constant....
In doing some quick research over at NLOC, it looks like it comes on at X temperature and looks to be constant once it comes on/off....
Title: intercooler for KB blower
Post by: Nate on November 18, 2005, 03:34:30 PM
Quote from: Paul Flockhart
Does pump speed vary with engine speed as a water pump would or is it constant?
even if it was just constant, you could hook up a fan with a thermostatic switch on it. im sure running that pump constantly would keep the fluid pretty cool unless you were realy pushing the car for an extended period of time, like on the highway with gears. but in going that root, you now add the weight of a intercooler, and a radiator for the intercooler, pluss the fluid for it. seems to loose efficiancy having to add something else to cool the cooler. personaly i think it may be better just to have the ducting and run a front mount, instead of haveing it ontop of the motor, then running lines, pump, and heat exchanger with maybe even a fan.
forgot to add... now that i think of it, i rember somebody telling me about running your ac system, or modifing one to flow the intercooler? any body hear of this, or is this the type basis for the liquid cooled intercooler with heat exchanger?
Title: intercooler for KB blower
Post by: RTStabler51 on November 18, 2005, 04:06:20 PM
Quote from: Manson
even if it was just constant, you could hook up a fan with a thermostatic switch on it. im sure running that pump constantly would keep the fluid pretty cool unless you were realy pushing the car for an extended period of time, like on the highway with gears. but in going that root, you now add the weight of a intercooler, and a radiator for the intercooler, pluss the fluid for it. seems to loose efficiancy having to add something else to cool the cooler. personaly i think it may be better just to have the ducting and run a front mount, instead of haveing it ontop of the motor, then running lines, pump, and heat exchanger with maybe even a fan.
I don't think you can really beat hte setup on the 03/04 Cobra motors / Lightnings. All the 'big' HP guys keep the factory intercooler setup. This includes the guys going to turbos, centrifugal etc.