Bell Intercoolers | Selecting Intercooler Assembly

This detailed walk through of the intercooler assembly selection and order process is provided to answer many questions concerning using our online core inventory system and assembly design system. While this walk through does provide useful information on our systems you may still have many questions regarding design of the best air/air or liquid/air intercooler system for your application. If so contact Technical Support and let our engineering team assist you with expert advice and information, all provided at no cost to you. Our philosophy is to provide you with the best parts and best information to ensure you have the best intercooler for your application.

Please note that Air to Air (Air/Air) and Liquid to Air (Liquid/Air) intercooler cores differ in construction and function. Be sure to select the proper core sized to the specific type of intercooler, Air to Air or Liquid to Air, to ensure that your turbo or supercharger intercooler system performs properly. Extruded cores may be used for very high boost Liquid to Air applications. Please contact us to determine if an extruded core might be suitable for your design.

In order to use the online inventory system you will first need to determine the flow patterns for your specific intercooler application. These flow patterns will provide you a point of reference to the accompanying diagram and will provide you with the key dimensions of your specific intercooler application. These dimensions are A (core thickness), B (core height) and C (core length).

The flow patterns that must be identified are Charge Air Flow and Ambient Air Flow or Liquid Flow. In layman's terms, Charge Air Flow is the intake air moving within the induction system, from the turbo or supercharger to the cylinders. Ambient Air Flow or Liquid Flow is the air or liquid that passes through the core to cool the intake air (Charge Air Flow).

Once you have determined the flow directions of these elements for your specific core, you can then select the various dimensions shown in the diagram. These dimensions are the key to using our online inventory system.

Also when selecting an intercooler core for your assembly, be sure to use our online inventory system to compare air flow requirements and find the core that best meets the needs of your application. Air flow for each core, shown in cubic feet per minute (CFM), is listed along with the core dimensions and core weight.

If you do not know what the air flow requirements are for your application, please contact our Design Services Group and we will help you determine the correct air flow volume.

To help you in the selection process we have included a sample order walkthrough. This sample order is shown in blue type throughout the following steps.

1. Select Intercooler Core Thickness (Dimension A)
The first step in selecting an intercooler core is determining the core thickness. In the accompanying diagram core thickness is represented by dimension A. On the page you will see the six core thickness options available. Select the thickness that matches your requirements.

In our sample order we will be selecting a core thickness of 2.25". We click on the 2.25" Core Thickness button and the 2.25" inventory chart is called up. If we want to see a different thickness we can simply click on another button to bring up the desired inventory chart. And, for those of you who want to see the entire core inventory we have you covered. Clicking the View All Core Charts button will open all charts. Clicking Close All Core Charts will close them again.

2. Select Remaining Core Dimensions (Dimensions B and C)
Now that you have selected your core thickness you may select the remaining core dimensions, Dimension B (Core Height) and Dimension C (Core Length). Simply refer back to the intercooler core diagram to be sure of the proper flow and dimensions in relation to your application.

In the inventory charts we have also included helpful information to help you in researching various core options (Air Flow and Total Weight).

Now that we have the 2.25" Core Thickness chart displayed we can select our remaining two dimensions, Dimension B (Core Height) and Dimension C (Core Length). For our order we need a core with a B dimension of 16.1" and a C dimension of 6.0". Consulting the inventory chart we find the core we need.

3. Select Tank Configuration
Once you have your core dimensions selected, write down the Price and Part Number information. You will need this information when you call in your order. Now click on the Select Tank Configurations button and you can choose the tanks that best fit your application.

There are several important elements to the Tank Configuration chart. First you will notice that the tanks are divided into two categories, Upper or Left Tanks and Lower or Right Tanks. A closer look at the diagrams in the chart shows a line drawing of each configuration, an Ambient Air Flow or Liquid Flow arrow, and an overhead schematic. It is important for you to refer to the flow pattern for your application to be sure we provide with the correct tank configurations on your assembly. There is also a selection for custom applications. Choose this if the configuration you require is not shown.

When you have selected the tank configurations you need, just write down the designator letter for the upper/left tank and the lower/right tank. This information, along with the core Price and Part Number will be needed when you place your order.

We have determined our core dimensions and found and written down the Price and Part Number information. Next we will select the tank configurations. We click on the Select Tank Configurations button. The Select Tank Configurations page provides us with two categories of tank configurations, Upper or Left Tanks and Lower or Right Tanks.

We know that our application is designed with tanks on the left and right side of the core. Before we select a tank we need to refer to the diagram to be sure we have the correct orientation to the Ambient Air Flow or Liquid Flow. This is shown as a large arrow in the tank diagram. Also shown in the diagram is an overhead schematic of the tank.

We have confirmed our flow patterns for our application and are ready to choose the tanks. We'll start with the left tank. Our design calls for an inlet/outlet on the bottom of the tank that exits to the back of the assembly. (The front of the assembly is the side where the Ambient Air Flow or Liquid Flow enters the core. The back of the assembly is the side where the Ambient Air Flow or Liquid Flow exits the core.) Looking through the chart we find that Tank B meets our needs.

Next we choose the right tank. For this tank, our design dictates an inlet/outlet at the top of the tank exiting to the back of the assembly. Looking at the diagrams we find that Tank D provides us with an inlet/outlet at the top of the tank and the inlet/outlet exits to the back of the assembly.

We have our tanks selected and we write down the designator letters for each tank, B for the right tank and D for the left.

4. Write Down the Information
You now have the core Price and Part Number information, as well as your tank information you need, just write down the information required to place your order (Part Number and Price). When looking at the inventory chart information, remember, if the part number appears in red it is not in stock. If the item you are looking for is out of stock please contact us to find out when it will be available.

Looking to the right of the dimension information we find useful Air Flow (388 cfm) and Total Weight (5.8 lbs) information. When doing initial research for our intercooler design we consulted this information to help in designing an efficient intercooler system.

Continuing to move to the right we find the Price ($406.00) and the Part Number (225161060) information. Write both of these numbers down and we will use them in the next step when we call in our order. We notice that the Part Number information is displayed in black, instead of red, so we know that the item is in stock and can be shipped for next day delivery, if we order before 1:00 central time.

5. Complete Your Order
You have all of the information you need from the inventory chart. Now just click on the Complete Assembly Order button to proceed to the next page. The Complete Assembly Order page contains the contact information required to place your order and confirm shipping.

Please note it is possible to place an order via phone, fax or email. However, to ensure accuracy of orders Bell Intercoolers will call to confirm placement before filling an order. If you need a core shipped for next day delivery please contact us by phone us to place your order (830-229-5330).

With our Part Number information written down we proceed to the Complete Assembly Order page. Here we find the contact information we will need to place our order. We see that we can phone, fax or email our order to Bell Intercoolers. We need this core in the shop tomorrow. We know it is in stock. We check the clock and see it is only 10:00 am central time. We pick up the phone and call the Bell Intercoolers order number (830-229-5330). The item is confirmed in stock and it will be in our hands tomorrow.

Having Trouble?
If you have any trouble with the online inventory system, please feel free to contact us (830-229-5330) with any questions. Also, if you were not able to find the core sizes you need in our inventory please call and we will try to help you find the correct intercooler core for your application.