Intercooler Core Sizing Calculator

Use crankshaft horsepower, BSFC and target AFR for the actual fuel. Fuel mass flow is horsepower × BSFC; air mass flow is fuel flow × AFR / 60. Fuel specific gravity does not change this mass-to-mass calculation. Preliminary constant-temperature cooling-sink model: heat duty = airflow × cp × temperature drop; required effective area = heat duty / (U × log-mean temperature difference). Air cp = 0.24 Btu/lb·°F. U and area density are illustrative inputs, not tested manufacturer data. Real cooling-air warming, fin efficiency, pressure drop and packaging require a core supplier’s performance data.