I'm trying to figure out if I should replace my old intercooler with a new OEM one or an aftermarket version - the fins are bent and it's just all dirty and beaten down. I think the Nissens OEM intercooler would be a good option, but there is this Racing Dynamics one which is around the same price point but is supposedly slightly larger.

Any recommendations?

 

Try cleaning up your old one and save a few bucks. They make special combs for straightening out radiator fins. Then give it a good cleaning.

 

I have that Racingworks (but bought it as a no name) and it works very well. Has some flow drop, but can take a lot more heat before it will heatsoak. It also lowers the IAT by a fair amount. I can only recommend it. You will need to do some modification, which I documented in my build thread (inc extra pics).

https://www.northamericanmotoring.co...ml#post4561676

 

What sort of modification? Seems like it would just fit in out of the box right, just might cover the spark plug boots.

 

I had the same idea, but I was wrong. You are thinking in the right direction See here & scroll down a bit: https://www.northamericanmotoring.co...ml#post4561676

 

Even the GP intercooler covers the spark plug boots as would any intercooler deeper than stock. After a while one becomes accustomed to removing intercooler couplings/boots.

Airtech makes a decent intercooler set up with a diverter.....

 

I 2nd the ebay oversized intercooler , I've personally tested it vs stock and its better in every way... even super easy to make a custom diverter to fit it , I have a post showing how if your interested. The intercoolers are only 100$ YOU CANT GO WRONG . mine DID require aftermarket boots though , for some reason stock boots just do not seal with it correctly.. so 140$ if you factor in new aftermarket boots then too.. Its a worthwhile easy mod I highly suggest it..

 

I guess the smart answer to that question is: "that depends".....

Depends on your mod's to the engine/drivetrain, depends on your budget and even depends on what altitude you typically drive. High altitude = boost loss, and depends on if you have a modified MINI with something other than stock for a supercharger, modified head / cam / exhaust.....ect

Remember, we are talking about superchargered induction here, NOT turbo.

If you have a daily driver and basically stock set up, a larger intercooler will contain increased volume of pressure and will always result in boost pressure loss, even up to 1.5 lbs. loss That's a huge sacrafice for going bigger on a relatively stock R53. Time wise, the "recovery rate" after heatsoak will be longer, and absent larger scoop to grab more air will run hotter than stock as well. Then one has to consider the internal construction of these intercoolers...including but not limited to the core design.

The stock intercooler and GP's have built in venturi's to guide the air flow through the center voids of the core. Most if not all the larger ones I've seen, boosted pressure meets a semi-flat wall inside the intercooler with a portion air being blocked in lieu of being directed through the intercooler. That results in both boost pressure loss and increased temps on the hot side of the intercooler...

About every aftermarket design out there have been thoroughly and equally tested under controlled conditions on a dyno....back about 15 yrs ago.

Found this Link !

Drivetrain Intercooler Cooling Tests