New custom intercooler from Bell came:
Core Size: 18" long, 10.5" tall, 3.5" thick.
Core Type: Bar & Plate
Fins: curved, louvered
Old one was a 1.97" thick Tube & Fin, with extruded internal fins.
Stock on top:
I went with a dual-tank on the passenger side, to minimize end tank volume & turbulence. End tank, passenger side comparison:
Comparison of passenger side end tank, top view. Stock on left, only tapers in 1 direction. Bell end tank also tapers width wise. Also, because of the bar & plate design, the end tanks can be fit to the width of the intercooler almost exactly:
Comparison of the fins (Bell is sitting atop the stock intercooler). Bell has greater fin density, and louvered fins.
A closer look at the louvered fins on the Bell, along with close up of welds:
Internal fins, huge difference from extruded stock. Also, notice the air passages go from one edge clear to the other:
Another picture where you can also see the air pipes run the entire width, thanks to the bar & plate design. As you can see, tube & fin type intercoolers, like the stock one, have narrower pipes, and less volume, even with the same intercooler width:
Detail on welds at the end pipe, plus detail on the beaded end to hold rubber pipe:
