I dont really see the purpose of a dual pass radiator other than to put the inlet and outlet on the same side. You cut the flow path in half and double the length so the resonance time should be the same and should receive the same level of cooling, but with more flow resistance. I'd think a 2" thick single pass plug and play radiator might be more than enough.
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Thicker radiators do have slightly more airflow resistance than thinner radiators but the difference is minimal. A 4" radiator has only approximately 10% more airflow resistance than a 2" radiator.
In past years, hot rodders and racers would sometimes install a thicker radiator and actually notice decreased cooling. They erroneously came to the conclusion that the air could not flow adequately through the thick radiator, and therefore became fully heat-saturated before exiting the rear of the radiator core. The actual explanation for the decreased cooling was not the airflow, but the coolant flow. The older radiators used the narrow tube design with larger cross section. Coolant must flow through a radiator tube at enough velocity to create turbulence.
The turbulence allows the water in the center of the tube to be forced against the outside of the tube, which allows for better thermal transfer between the coolant and the tube surface. The coolant velocity decreases, and subsequently its ability to create the required turbulence, increases in direct relation to the increase in thickness. If the thickness of the core is doubled, the coolant velocity is halved. Modern radiators, using wide tubes and less cross section area, require less velocity to achieve optimum thermal transfer. The older radiators benefited from baffling inside the tanks and forcing the coolant through a serpentine configuration. This increased velocity and thus the required turbulence was restored.
Radiators with a higher number of fins will cool better than a comparable radiator with less fins, assuming it is clean. However, a higher fin count is very difficult to keep clean. Determining the best comprimise depends on the actual conditions of operation.
Double pass radiators require 16X more presure to flow the same volume of coolant through them, as compared to a single pass radiator. Triple pass radiators require 64X more pressure to maintain the same volume. Automotive water pumps are a centrifugal design, not a positive displacement, so with a double pass radiator, the presure is doubled and flow is reduced by approximately 33%. Modern radiator designs, using wide/thin cross section tubes, seldom benefit from multiple pass configurations. The decrease in flow caused by multiple passes offsets any benefits of a high-flow water pump.
Gross flow radiators are superior to upright radiators because the radiator cap is positioned on the low pressure (suction) side of the system. This prevents the pressure created by a high-flow water pump from forcing coolant past the radiator cap at high RPM. As mentioned earlier in the radiator cap section, an upright radiator should be equipped with the highest pressure cap recommended by the manufacturer. The system will still force coolant past the cap at sustained high RPM.
My plan was to place the 20x10 intercooler in front of the top of the radiator and dedicate 3.5 of the grille openings to intercooler via a duct. The remaining 3.5 openings would be allowed to flow directly to the bottom of the radiator for direct cooling. This would allow increased cooling of the coolant by not pre heating the air with a 350 degree air charge, but also force air through the far more efficient CAC. With a bar and plate intercooler you can expect about 45% of the frontal area is actually flow area for the cooling air so it works out to about 50% of the grill opening. You would still get the full grill area flowing to the radiator but 1/2 of it would not be pre heated by the CAC.
Now a 10,000 CFM fan, that I would be interested in.
Take a look at Bell Intercoolers. You can custom order pretty much any sized core with a variety of end tank configurations. Each end tank can be different if you want. I bought one from them and posted here about it a couple weeks back but havent gotten around to the install with work travel.
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