Howdy all,
 
Well, I took a couple intercoolers to the hanger, and tried them on for
size.  The FC model would probably go in the right cheek, without too much
effort, though I'm worried that I'll pressurize the back of my radiator and
oil cooler if I let too much air flow through it.  What to do, what to do...
 
I also did some more research on charge temps, and intercooler
effectiveness.  It seems that 70F is about the best temp drop that you can
hope for with a good intercooler, at high boost.  Unfortunately, size
counts, and neither the FC nor FD intercooler is what would be considered
"good".   Adequate might even be a stretch, especially for the FD model.  In
the scheme of things, <=70F really isn't a deal breaker, and I'm starting to
believe it falls in the category of refinement, more than necessity, when
talking about 10 psi or less of boost, particularly when the higher boost is
only used at frigid altitudes.  Turbo Tom considers it a necessity, but I
have to wonder what his criteria is.  If I had a car, and were limited to X
psi of boost, I would consider intercooling necessary to make the most power
possible.  Since I should easily have more power than I could ever need, I
don't see the intercooler being quite as essential.   What does this all mean.  Well, I'm going to fly it like it is, and use up
to 5 psi for takeoff.  At altitude, I'll go for the gusto, but will try to
limit myself to 50" MAP, or 12 psi of boost over ambient, whichever comes
first.  This should make a world of difference, and I can move on to
something else.   Cheers,
Rusty