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I disagree that a larger intercooler will not give you higher horsepower. It definitely will under the right circumstances. Less flow restriction and reduced engine input temperatures will definitely be beneficial. Turbochargers heat the air even at moderate power levels.
 

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To heat soak the intercooler I think you would also have to be doing something that demanded high power and alternated with no forward motion (like solo, drag racing, or stop-light racing). Any road driving / racing will include enough periods of lower power demand at a high enough speed to force enough air through the intercooler to prevent heat soaking.
I would say that it is very easy to notice heat soak with the tune on my car. The power definitely starts to drop off after just a few minutes of driving with high engine load, and the effect is much more pronounced when the ambient temperature exceeds 15°, on a hot day of 30°+, forget it, power is way down, similarly on a cool day in winter, the problem isn't really there at all. Without the tune you really don't notice any difference, though, the stock intercooler is more than enough.
 

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I would say that it is very easy to notice heat soak with the tune on my car. The power definitely starts to drop off after just a few minutes of driving with high engine load, and the effect is much more pronounced when the ambient temperature exceeds 15°, on a hot day of 30°+, forget it, power is way down, similarly on a cool day in winter, the problem isn't really there at all. Without the tune you really don't notice any difference, though, the stock intercooler is more than enough.
I wasn't thinking about running the cooler that much over its design spec with a tune.
 

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I can tell you, if you get a HFC, CAI and an AM IC, you can get an extra 20-40hp out of a dyno tune. My car was over 350bhp when he had to back it down due to knock from heat soak. He said he didn't want to risk me tracking my car and blowing it up. But he told that with the HFC and IC I would have had no issue with being well over 350bhp. I'm at about 325bhp without any of that.

For the record, the LTG engine will see over 400bhp with those mods and a dyno tune. He had an ATS at the shop pushing over 400hp with those mods. But, the motor that ZZP tuners really love is the 3.5L eccoboost from Ford. Every one of their employees was driving a vehicle powered by the 3.5L. He said they make well over 600hp easily with nothing more then a tune.
 
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