Well with the help of some of the forum members, I've decided to go ahead and build an air to water aftercooler for the 530's VFE system. At present the addition will be combat summertime heat soak, and maybe an increase in boost later on.

First things first. The chargecooler. Does anyone have experience with products from http://www.bellintercoolers.com/ ?
They seen to have a pretty big selection of tank styles. Which greatly expands potential designs. Hmmmmmmm.... How to make it work.

I would study the E39 for plumbing space to see if you could use an off the shelf EBay air to water intercooler in the aftercooler style. There are now a few different configurations and sizes and the prices are great.

Philip Bradley

Study your plumbing space, but also you need to make some calculations regarding your current air flow and outlet temp of your compressor, and then decide how much heat you would like to extract. That will set the core size that you need.

Then you need to look at the front heat exchanger portion as well.

Great quaility cores. I use them often.

The primary problem seems to be space and potential plumbing. The RMS stlye kit seems to be a good direction (pretty much the style we will probably go in). Unfortunatly the actual charger has a slightly different exit, the trottle body seems to be positioned 6-8" lower, and there is a disa valve in the way. All of which is OK, because half the fun is reseach / building.

The other option could be to drop the plumbing straight down out of the charger into the cooler. Locate the cooler somewhere around the oil pan & driver's suspension. Them route it back up. Seems to be too much stuff.

Trying to K.I.S.S. setup ideas.

Great quaility cores. I use them often.

That's great to hear. Knowing there is a quality part mfg is a very nice starting point.

OK, 1 air to h2o aftercooler core with dimensions of 3.5" w, 6" l, 6" h is $176. Which probably doesn't cover fittings. This would be for an in line set up. Which makes the most sense, but has the least amount of room.

All the other plumbing (tank, pump, selonoid, an heat exchanger) can be easily put into place. The real challenge is the cooler itself.