Radiator & Intercooler Kits

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NEW COSWORTH RS500 Intercooler - $119.95

1:1 replica of the factory Cosworth RS500 IC, bolts up in place of the A/C condensor.



(NEW XR4Ti Shorty Radiator  &  Large Intercooler Combos are in development.)

A/C must be removed to run the large intercooler. Want to keep A/C? Inquire about the small IC combo.

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How well does it cool since its so much shorter than the stock radiator?

Outperforms the stock radiator. Cooling capabilities actually improve over stock.

 How do you bolt the stock "puller" fan to this?

The stock puller fan cannot be used with this radiator.  12" universal mount radiator fans can be found very inexpensively to use. ($29.95 at http://www.siliconeintakes.com/ FYI).  You can even fit 2 of those fans side by side if you feel necessary, however one will work just fine in most applications.

I have an automatic XR, what about the transmission cooler in the stock radiator?

Consider this to be a good opportunity to upgrade your radiator as well as trans cooler.  Most auto parts stores sell external transmission coolers for under 30 bucks and will work much better that the stock one thats inside the factory radiator. 


See below for our special lower radiator hose to compliment this radiator.

Dayco hose # 71679 from your local parts store is a suitable upper hose you can use with this radiator. 

Bypass hose routing?

The middle port on the 1985-1988 coolant bottle can be capped off just like it is from the factory on the automatic XR4Ti. The lower gravity feed hose from the coolant bottle should be T 'ed into the upper water pump hose (which is also done on the factory automatic XR4Ti).  Installing a 1985-1988 automatic XR4Ti "Y" hose will give a clean, factory look to your install.





Whats the best way to regulate boost now with an intercooler installed?

We highly reccomend a manual boost controller from boostvalve.com and installing it per their instructions specific to the XR4Ti:  http://boostvalve.com/ford-2.3l-turbo.html



What blow off valve do you recommend for this intercooler installed on an XR4Ti?

We reccomend using a bypass valve instead of a blow off valve if you are still running a Ford air meter on your car due to the fact a bypass, or recirculating valve keeps the metered air in the system instead of venting it into the atmosphere. Driveability will be much better with a bypass valve installed.  If you want to run a blow off valve make sure it is a dual piston style blow off valve.  We offer both types of valves and a silicone T-hose that makes installation simple.


Please visit the other section of our website title BOV / BPV valves, intercooler hoses and pipes for the 90° elbow and turbo to intercooler "S" pipe you see used in the installation pictures.  

The large intercooler will take up the space formerly used by the AC condenser, so AC must be removed.  Highy effecient intercooler has minimal pressure drop and will easily support up to 400+ HP

We reccomend removing the factory rubber isolators used with the stock raditors and mounting this unit into place without them. Good news for owners with lowered cars - you will pick up an extra  3/4" of ground clearance when mounting it this way.


What is the purpose and/or advantage of an intercooler?
The purpose of the intercooler is to remove the heat in the air charge that the turbo/supercharger puts into the charge when compressing it. There are two advantages: Reducing the heat in the air charge increases the charge density (more molecules of air per cubic foot), thus increasing the potential for making more power. Reducing the heat decreases the tendency of the combustion process to knock (detonation).

How does the intercooler affect the power output of the engine?

Power is dependent on the density of the air charge. By decreasing the temperature the intercooler increases air charge density, therefore, the power is increased. Typically, the magnitude of the increase will be between 10 and 20% for the average (street) boost pressures.

Is some intercooling better than no intercooling?
No. It depends on the design of the intercooler, and there are two factors involved; efficiency (how much heat is removed) and the flow restriction (lost pressure) created by the presence of the intercooler. Regardless of the efficiency, if too much pressure is lost, then the intercooler is either useless or can actually decrease performance .

What are the differences between short tubes and long tubes?
The longer the tube the greater the pressure loss accompanied by a slight increase in efficiency

What factors affect efficiency of an Air-to-Air Intercooler?
Frontal area: This is a rapidly decreasing function. If the proper core size is used, then doubling it will definitely not double the efficiency. More likely, doubling the core would raise the efficiency about 5% and cost twice the necessary amount and add substantially to the weight.

Plate Area: Plate Area (the sum of the Core-Plate Area which is exposed to the Atmosphere) is directly proportional to the frontal area and the thickness. Thickness, however, is a double-edged sword. With the greater thickness, the plate area increases but less ambient air can penetrate the thicker core to offer cooling.

Ambient air quantity: It is very important to insure that air coming in the front of the car will actually go through the intercooler.

How does one measure the efficiency of the intercooler?
The efficiency is defined as the ratio of the temperature removed from the air charge by the intercooler relative to how much temperature is put into the charge by the turbo/supercharger.

For example: If the turbo/supercharger puts 150 degrees F into the charge when compressing the air, and the intercooler removes 110 of those degrees, then the efficiency is:

Eff = 110 / 150 = .733, or 73.3%

What factors affect the pressure or flow loss?
The internal flow area is the major controlling factor. Tube length is the second biggest consideration, as a tube twice as long as another will have nearly twice the drag at the same air velocity. Tube entry and turbulator density play small roles and can be considered insignificant. When configuring the orientation of the core in a given space, always position the core to offer the shortest length tube and the most number of tubes. Clearly, this optimizes the internal flow area.

What ranges of pressure loss can be expected? And what is acceptable?
For good solid performance, the pressure loss across the intercooler ought to be kept to less than 1.0 to 1.5 psi. If any pressure in excess of 4 psi is measured, then the intercooler is not suited for the job and certainly harming the performance.

If the boost is raised is it necessary to increase an otherwise proper intercooler?
Very seldom. While the loss through the intercooler is proportional to the flow (CFM) squared, unlikely the change will be of a magnitude that requires a bigger intercooler. If dramatic changes in flow are created, say 50%, then the flow loss would increase by 1.5 squared, or 2.25, and that would prove excessive thus strongly suggesting a larger intercooler.