Garrett Bar and Plate Intercooler Core 4″ Thick
Charge Air Coolers
Utilizing advanced Aerospace technology, Garrett Intercoolers offer superior fatigue protection for the high boost pressures and temperatures of today’s extreme engines. With over 75 years of charge air cooler experience, Garrett remains ahead of the industry in intercooler design and function making it the number one choice for some of the premier names in the performance car industry – Roush, Saleen, Mercedes-Benz AMG, Ford SVT, GM, and McLaren have all turned to Garrett to intercool their hottest models.
Garrett now offers this expertise and quality to enthusiasts, in a full range of intercooler cores that are manufactured in-house by Garrett technicians. The Bar and Plate construction offers high performance in a compact design using high strength vacuum-brased aluminum alloys with advanced fin designs to ensure greater heat transfer effectiveness and durability. From Air-to-Air cores sized for Sport Compact cars to Air-to-Water cores capable of supporting 1000+ horsepower, Garrett can provide optimum performance for nearly any application.
4″ Thick – “Hot Flow Width” Intercooler Core Options
#848054-6002 w/ 22.0″ L x 4.0″ W x 9.0″ H — Rated at 660hp and Weighing 17.4lbs
#486827-6002 w/ 23.7″ L x 3.8″ W x 12.0″ H — Rated at 1000hp and Weighing 23.7lbs
Charge Tubing Calculations
The duct diameter should be sized with the capability to flow approximately 200 – 300 ft/sec. Selecting a flow diameter less than the calculated value results in the flow pressure dropping due to the restricted flow area. If the diameter is instead increased above the calculated value, the cooling flow expands to fill the larger diameter, which slows the transient response.
For bends in the tubing, a good design standard is to size the bend radius such that it is 1.5 times greater than the tubing diameter.
The flow area must be free of restrictive elements such as sharp transitions in size or configuration.
- Tubing Diameter: velocity of 200 – 300 ft/sec is desirable. Too small a diameter will increase pressure drop, too large can slow transient response.
- Velocity (ft/min) = Volumetric Flow rate (CFM) / Area (ft2)
- For twin turbo setups, divide the flow rate by two (2).
Charge tubing design affects the overall performance, so there are a few points to keep in mind to get the best performance from your system.
- Duct bend radius:
– Radius/diameter > 1.5
- Flow area:
– Avoid area changes, sharp transitions, shape changes
- Available packaging space in the vehicle usually dictates certain designs
Another important factor in selecting the correct intercooler is the end tank design. Proper manifold shape is critical in both minimizing charge air pressure drop and providing uniform flow distribution. Good manifold shapes minimize losses and provide fairly even flow distribution. The over-the-top design can starve the top tubes however. The side entry is ideal for both pressure drop and flow distribution, but it is usually not possible due to vehicle space limitations.
Proper mounting of the intercooler increases the durability of the system. Air to air charge air coolers are typically “soft-mounted”, meaning they use rubber isolation grommets. This type of mounting is also used for the entire cooling module. The design guards against vibration failure by providing dampening of vibration loads. It also reduces thermal loads by providing for thermal expansion.
Benefits of Isolation:
- Guards against vibration by damping loads
- Reduces thermal loading by providing for thermal expansion