Anthony, even though we are blessed with decent weather here in AZ, we do have to deal with the 6 months of summer heat that is detrimental to IATs on our turbocharged rides. Justin's air-to-air intercooler is definitely sized to handle the big HP of his Goblin. Here in the desert you can never have too much cooling, as we know.
Granted, you already have your car built and making some mods to gain better cooling may not be right for you. An increase in the heat exchanger capacity with more surface area and moving it to a different location, out from behind the radiator, should help. Another option is to add the NACA ducts if you plan to keep the heat exchanger in its current location, but not sure if you want to cut holes in your hood. Another thing to consider is the flow of air in the front of the car. The open 'floor' under the radiator area, in front of the forward firewall, does not promote good air flow coming through the radiator or heat exchanger, plus contributes to front end lift. Adding a 'floor' to this are can help, as exit air flowing out the sides of the car is better than trying to flow out the bottom. These are just my thoughts based on the 'standard' cooling provided by DF.
My plan is to go big and have redundant cooling to get IATs at least to ambient temps. I have posted some of this in my build log, but this thread seems to be good place to put it all together and share with those who may have the same need for over the top charge air cooling. The plan is to run the turbo outlet into a 2.5 inch air-to-air intercooler that feeds into a 3 inch air-to-water intercooler then into the engine intake. The air-to-air intercooler (what I am calling my precooler) is a 12X9X2.5 inch core that will have a 10inch cooling fan. The air-to-water intercooler is a 11X9X4.5 inch core that will be cooled by dual KZ750 radiator heat exchangers with 7 inch fans and additional water spray cooling. I am building sidepods to house the heat exchangers and water spray system. I am also looking at a Snow (or similar) intake injection system, but have not committed to purchasing one yet.
The thought is the precooler will remove some of the charge air heat, which will be variable with the ambient air temperature, especially here in AZ. The air-to-water intercooler, being sized for a 500+ HP application, should be able to remove the remaining heat to get the IAT to at least ambient and hope to be able to bring it below ambient with the evaporative cooling from the water spray system. I did a quick thermal analysis to determine the dual KZ750 radiators should be adequate for the mass of the intercooler. I plan to monitor the charge air temps at the turbo outlet and at the engine intake to see what the actual temperature delta will be. All of this will be a tight fit and the fusebox next to the engine will need to be relocated, probably up front near the BCM and battery. The plumbing for the charge air will be a challenge to route and keeping the AZ heat out of it, after going through all of the intercooling, will require some insulation - not going to look very pretty, but will be functional.
let me know if you need someone to bounce ideas off of, as I am just a short drive away. Besides, I still have not seen your car in person yet.
