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Good questions!
I have not done the flow calculations for the air side of the core, but it is sized larger than the supercharger discharge port.
I should run the numbers to be certain, but my thought is that it'll all work out in the end.
The end tanks are going to be 0.5" thick and mount to the plate the core is being welded to, with the water passages going through the upper supercharger mount plate to a bank of 0.5" fittings at the edges. I'll have to do a render and post it so everyone understands how the water passages are being dealt with.
Suffice it to say, the tanks shouldn't pose much of a flow restrictiin to either water or air.
Once the rough stair-steps on the casting are smoothed out the flow to 1 and 4 should be about the same as the middle two. I'll check with a shop vac and manometer to be certain once everything is finished.
The intercooler is sized as large as possible for the space it has to fit into, I've hit physical constraints on length/width/depth.
The delta-T at the supercharger operating point is 150°F, so at ambient of 65°F my IAT would be 215°F, which isn't that good in my opinion, so the intercooler should at least be able to drop it lower than that.
I'll have to run the actual numbers and get back to you on this, I should have done it from the start...
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