GT550-S550-720HP Intercooler System Components and Packages

Department Of Boost Super Single 22gpm 742cu in Intercooler System Upgrade Package

department of boost super single intercooler system upgrade

Why don’t we supply “good” intercooler system components with our base kits? Well, because no one else does. The only way we can be on the same “pricing playing field” with other companies is to spec our base kits the same way they do.

Arguably the most important supporting modification you want to consider is to upgrade the intercooler system (not the intercooler itself, that is locked in the manifold, we’re talking about the supporting components). When you compress air (boost) it creates heat. On average about 12-13deg per 1psi of boost. Too much heat causes engine detonation/knock. To keep the engine safe the cars computer (ECU) subtracts ignition timing when the temperature reaches 136deg. The further it goes over 136deg the more ignition timing is subtracted. This reduction in ignition timing has a very large impact on how much power you’re making. It doesn’t take much to knock you down 75-100hp. And that’s no fun. You paid a lot of money for that power.

Not one single blower kit comes with intercooler system components that are capable of keeping your inlet air temps (IAT’s) down to a safe/full power level. In fact, most of them can’t even be modified to a point where temps are safe/you have full power all the time no matter what you throw at them. It’s the blower industries dirty little secret.

With the correct supporting components our intake manifolds/intercoolers can support massive amounts of boost. The intake manifolds/intercoolers you get with other kits still can’t correctly support 10psi of boost even if you throw every top shelf/big dollar intercooler system component available at them.

<Scroll past kit info to read tech info>

Super Single 742cu in 22gpm Intercooler System Upgrade Kit

Kit includes:

 -Department Of Boost POWA Pump

-Department Of Boost Super Single  heat exchanger

-Partial bypass mod plumbing for higher water speed systems

-All lines, clamps, fittings, etc.


 -22gpm of water flow

-742 cu in of heat exchanger core volume and the ability to run up to a 1” hose (other heat exchangers are limited to .75” hose)

-1.00” hoses

*****Power Draw Warning*****

The water pump draws 26 amps. Which is quite a bit. For perspective most pump have a 3-5 amp draw. You stock alternator only puts out 135 amps. You are going to want one of our “Bulletproof” Denso alternators is you want to run this pump. It’s also a really good idea to gauge up all of your batter, alternator and ground wires/straps. This is big boy level stuff here.

Intercooler System Requirement Tech

Intercooler systems are incredibly complex. There are a lot of variables. Change one, and everything else in the system changes. We’re going to try and keep this short so this is distilled down to something as simple as we can get it.

We have three designations for intercooler system performance:

-Bulletproof – Bulletproof is best compared to how your cars engine cooling system performs. You never think about over-heating, right? That’s because modern cars don’t over-heat. Of course, if you want to do something extreme like hold the throttle wide open while you’re only moving at 2mph (you would need to be in the mud with a truck to do this) it would over-heat. Or, if you’re a really fast driver and it’s really hot out you can get a stock car to over-heat on the road course over a 20min period. These are pretty rare occurrences. And if you’re doing that sort of thing, you probably already know that you need to address cooling. But all in all, modern cars don’t over heat. That is how we define bulletproof.

-Pretty Darn Good – This one is a bit harder to define. Most of the time you will have no temp issues. But if you let’s say want to do three back to back to back 12sec wide open throttle runs you may get a little hot and drop a few HP toward the end. Or if it’s absolutely blazing hot out you may be limited to one 12sec wide open throttle run before you need to give it a short break to recover. And if it’s blazing hot out, you have been sitting in stop and go traffic or just driving at a slow pace stopping at a lot of lights on surface streets you may drop a few HP at the end of a single 12sec run. Pretty darn good is pretty darn good and way, way better than what 98% of blown cars have going for them.

-Crap – Crap is just what it sounds like, it’s crap. Most of the time a crap system will not even give you 6sec of wide open throttle before it’s murdering power. Then it needs a long time to cool down before you can do it again. If it’s hot out it will never cool down as long as you’re still driving the car. To cool them down you have to turn the car off and let it sit for hours. Back before we were Department Of Boost we had a car like this (most blown cars are like this). It was very disappointing. It was the catalyst for the creation of Department Of Boost.

On average what you get with blower kits is a pump that will move 5-6gpm (gallons per minute) of water and a heat exchanger with 150-250cu in of heat exchanger core volume (these numbers will mean something in a minute). The GT450-450HP has 6.5gpm of water flow and 264cu in of heat exchanger core volume standard.

After years of collecting data we have been able to put together a chart of system requirements for different boost levels and situations. The chart below assumes that a composite heat barrier is in use. See the “modifiers” section at the bottom for info on the absence of a composite heat barrier and other things. This chart is not a “rule”. It would be impossible to make something that focused with all the variables that are in play. But, it’s 95% of the way to “rule”. And considering no one else has done the amount of testing we have and then put it in chart form, this is as good as it gets as far as data goes.

As you’re looking at the chart below keep this fun fact in mind. Even if you throw the best intercooler system components ($2500+) at the other blower kits manifolds/intercoolers the highest water speed you will see is 12.75gpm. Additionally, there are no composite barriers available other than the GT450’s.


Everything under “Pretty Darn Good” is “Crap”. We didn’t bother putting that in the chart.

ic system requirements -- if you want us to send you the spreadsheet, please contact us

In summary you really want to take a look at upgrading a few components now so you don’t buy them twice (once when you get the kit, and again when you upgrade). If you upgrade now the value of the standard kit parts is subtracted (credited – pricing already reflect that) toward the bigger stuff.

If your future plans include more boost keep that in mind when spec’ing out your intercooler system.

Heat Exchanger Fans:

We don’t offer heat exchanger fans. Not because we can’t, but because we won’t. They’re a gimmick. Here is an article explaining why:

GT550-S550-720HP Intercooler System Components and Packages