BD’s free flowing Charge Air Cooler (CAC) - or intercooler - design with streamlined external air passages improves engine cooling while offering less fan noise and less blade resistance, plus, improving engine power and efficiency of the radiator and air conditioning heat exchangers. Designed through testing at 100+ psi turbo boost pressure and 500oF turbo outlet temperatures, our extra thick cast end tanks with support struts have integrity and long life without ballooning and cracking. Stuffed Tube designs are commonly used on stock applications with boost pressures of 20-40 psi and 200-300 OF inlet temperatures. The tubes have a thin wall and 82% heat conductivity transfer. Higher boost pressures and temperatures will cause breaking of fin-to-wall welds resulting in tubes ballooning and reduced heat transfer. Micro Extruded Tube design is for applications producing 20-100 psi of boost pressure and inlet temperatures of 500+OF. The tubes have a 0.025” wall thickness and designed enhanced inner fins that add to performance and already strong support structure resulting in a 95% heat conductivity transfer. No cracking or separation occurred when tested at over 400 psi. The lower the turbo boost pressure drop across the CAC (inlet vs. outlet) the higher the volume flow — the more volume of air that can fl ow through the CAC and the higher the turbo boost pressure will result in lower exhaust gas temperatures (EGT). BD’s Cool-It CAC’s are designed for performance diesel engines.