The intercooler is always going to be around ambient temp. The turbo isn't making any real heat until you start compressing the air, (boost) so you only really need the fans on to pull air though the intercooler when your in boost to cool the compressed air.

The way your intercooler is mounted, you get very little air flow though it. Turning the fans on only when you are in boost will pull air though it when you need it.

Also, it you put a 2" strip of plastic and mounted it vertical, sticking down at the back of the cooler, it would force a LOT of air though the cooler when your cruising down the road.

 

KB is right make an intercooler "spoiler" to go with your setup

 

Thats how the Procharger intercooler mounts also, but it has about a 3 inch strip that runs across the back of it to scoop up the air so to speak. I like the fan idea and have seen it on a couple of other trucks too. I wouldnt worry about a pressure switch. I would however look into tapping the power wire into a 12 volt ignition source. That way they would just come on whenever you start the truck. Wouldnt have to worry about anything other than driving it and hauling ***
I will probably end up adding some fans to mine as well.

 

watching those two guys on muscle car on spike not too lone ago,
he formed a peace of sheet metal to work as a full shroud for a radiator with a single fan.
looked like a good idea to do to the intercooler, one single fan that can pull enough cfm's
through the intercooler to keep it the temps down.

my core is 24 x 12 so one 12" fan should be enough to do the job.

 

Well, i like to play off road from time to time, thats the other reason for the on/off switch, have to kill them for water crossing and water holes.

Any one got pics of this spoiler thingy?

 

Here's an example, using my mad paint skills . You could even make it out of some clear acrylic from Home Depot and you would hardly even notice it. You will be surprised at how much a 2-3 inch air dam right there will improve air flow though the intercooler.

 

Hhmmm... I might try that, i could always use 3M Tape so it could break aways if needed...

 

Here are couple of pics of the Procharger intercooler