It will be a multiple straight through tube design sourounded by the fluid bath, possibly 3/4" aluminum tubing or 1/2", maybe even 3/8" if what everyone says about slowing the charge down to help it get cooler holds true.
I will try and keep the length if the cooling section as long as possible to draw as much heat out of the charged air as I can.
The unit will be cooled mainly by a pump that circulates the fluid through a small radiator or heat exchanger that is mounted either in front of the engines radiator or mounted at a slight angle under the vehicle.
I have not decided as of this point where I will put it for sure but am figuring out where it would work best considering I want to use some type of cooling can for extreme heat situations.
The pump will also be switched so it does not have to run all the time, most likely wired so I can run it even with the vehicle off but the ignition key in the on position to help pill heta from the charged air pipes.
I will keep you guys in the loop as I build this thing and be asking more questions as well.

 

The smaller and the more tubes your can get, the better it will work. You will need as much surface area as you can get for heat transfer. I would step up you multiple tube section to at least 3 1/2" to 4" I.D. or more to get enough flow and surface area. But sounds good. And I want to see pics!

 

I was thinking about using a 6" O.D. aluminum housing for it actually!

 

yes, but how big will the flow part be?

 

Sorry, the input and output sections will be the same diameter as the setion of STS tubing under the passenger rocker panel. About 3" I guess, I'll have to measure it to be sure. The ends will step up from the STS pipe diameter to the I.D. of the intercooler housing.
I intend on replacing a section of the STS piping with this unit. I have seen a similar unit on a Dodge on a web site some where. I'll try and find it for reference.