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KEY POINTS TO INTERCOOLER DESIGN So if you look at our core you can't really even see welds because we made it as wide as we could (while still fitting between the AC lines and being able to connect to the boost tubes). Wider is better as there is more ambient cooling surface. Because of the high IC inlet temps, a bigger core on the Ambient side is important. The hieght of our core is also as big as we felt would still be functional. We could have gone taller but its just that much less of the core that gets air flow. So we made it as big as we could. We didn't purposely make it bigger than others, we made it as best we could, which just happens to be bigger. Maybe we need to use that on our site...... There are lot of factors that go into making a proper intercooler, price, fittment, installation ease, size and functionality. We feel we have a very good balance of all these things. And with proper ECU tuning, a PERRIN Turboback Exhaust, and this intercooler, you can turn your EVO into a PERRIN Stage 3 monster like this below... Charts and Articles: