I understand the concept of an air/water intercooler, but I've never actually seen inside of one and exactly how it works. Does anyone have any in progress pictures or one?

Any design ideas/tips? What works, what doesn't?

Any ideas are welcome, thanks!

 

i have no pics, but the main goal is surface area. typically to maximize SA with minimal pressure drop or drag , honeycomb or hex tube is used to pass the air through. placing 4 hex tubes together leaves a square "void tube" that can be used to pump coolant through. so in a cluster of hex tubes, each hex tube will have 4 sides that are in direct contact with coolant. and, the longer the cluster the more heat can be removed from the air.

it's not easy to build a sealed cluster from hex tubing (1/8" tubing). i think adhesives are use to bond tubes together. the ricky part is the cap the ends so to seperate coolant from air.

 

Hmm I understand how you can make the square "void tube" but not sure on how to build the ends...

Also can't you use old intercooler cores and just pass water through the tubes, instead of air somehow?