**UPDATE**
For those of you who were following this:
I purchased some materials this past weekend to make up my prototype. This project is still very much on the way, but not in it's original format. The down side is it's been delayed a bit, but I still fully expect it to be done in the coming months. The upside is that in my new format I'll be able to do some better performace testing compaired to a factory chiller. I will have details of pressure drop, as well as actuall cooling of the charged air, the two most critical methods intercoolers are judged by.
Ryan