Recently other tuner shops have attempted to imitate the Helix Stepped Core Intercooler’s (SCI) unique design and success. Given the large inquiry about what positions an intercooler as the best offering, I figured I would take this time to talk about the science and innovation put into the Helix SCI. Placing the stepped intercooler core design aside, Helix built in other innovations that are BMW/Mini intercooler market first.
Many of you have heard the terms “Tube & Fin” and “Bar & Plate”. Both of these terms refer to intercooler construction. These intercooler construction methods make up the majority of intercoolers offered to the BMW market. Each has their Pros & Cons with weight, air flow, thermal reserve, thermal conductivity, ect. Below is a picture of a Bar & Plate (top) and Tube & Fin (bottom) intercooler.
The image below describes the charge row airflow characteristics of two construction types; however the Bar & Plate image is a bit exaggerated.
The image below describes the efficiency associated with orifice inlet design. Tube & Fin inlet design has an efficiency of on .53. The Bar & Plate inlet design has an efficiency of .80. Take notice of the inlet design with a .98 efficiency rating.
The image below was taken by a customer of an intercooler that attempted to imitate the SCI design. Notice the wide flat plates between the charge rows and the sharp 90 degree transition into the charge row. This construction is consistent with a Bar & Plate design and is rated at only .80 air flow efficiency.
Below is an image of an intercooler from a tuner shop that also imitated the Helix SCI. Looking inside you can see that the construction is Tube & Fin. Notice how the charge rows protrude into the end tank air space. This inlet design efficiency is rated at a dismal .53.
The Helix intercooler is constructed from a Bar & Plate design, but Helix designed and invested in an innovative custom extruded header bar. The Helix header bar is half round and serves as a bell mouth/velocity stack into each charge row on the ambient side as well as charge row inlet and outlet. This transition is rated at .98 efficient. The Helix Stepped Core Intercooler is the only intercooler that offers these innovations. This is one more innovation that allows the Helix intercooler to outperform imitators and other offerings.
The lesson is: You really do get what you pay for.