I "think" the size is PLENTY big enough. Look at the size of a trans cooler. There is a hole in the bumper to give it airflow.
I will weld some bungs on the inlet and outlet piping of the intercooler so I can monitor pressure and temp drops. Then maybe make a run without the bumper and see the difference. If it's huge, I might try to make a duct from the hole in the bumper to the heat exchanger. Or just cut the opening bigger.
That heat exchanger will be for the first stage. I will probably put 2 smaller ones behind the grill and an a/w barrel style cooler in the stock airbox location.
I just got 2 bosch cobra water pumps for 120 shipped from ebay!! :-)
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2003 E-350 7.3, 38R, DIY intake, 4" turbo back, Swamps Tunes, forged rods, exhaust ported heads, comp 910's, h-11's, stealth twin pumps, 300cc hybrids, racerx trans and tc, water injection
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