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Introducing the Conflux Barrel Intercooler

A premium water‑to‑air cooling solution for high‑performance builds that demand compact packaging with controlled pressure drop. It combines high effectiveness, low pressure drop, and tight packaging in a product engineered by heat transfer experts and supported by correlated analysis, test data, and application development. Available in production ready sizes to fit common hose sizes with configuration capabilities.

Proven intercooler technology used in top-tier motorsport, including Formula 1, WRC, and IMSA, and validated in premium OEM programmes through rigorous testing and application development.

Production-Ready Barrel Range

The 4.5" Barrel

Optimised for engines up to 400kW

Dimensions: 140 x 133 x 155 mm

Dry Weight: 1.5 kg

 Request Performance Data

The 5.0" Barrel

Optimised for engines between 300kW to 600kW

Dimensions: 160 x 150 x 190 mm

Dry Weight: 2.2 kg

 Request Performance Data

The 6.0" Barrel

Optimised for engines between 500kW to 900kW

Dimensions: 177 x 171 x 225 mm

Dry Weight: 3.4 kg

 Request Performance Data

Need More? Configure the Intercooler to Suit Your Application

If your requirements for a barrel intercooler sit outside the three production-ready sizes, it can be configured to your application.

Review the configuration options below and get in contact with us to discuss your project.

Barrel Length

Up to 390mm

 Air Connector Diameter Size & Type

Diameter - Up to 203.2mm (8.0 inch)
Connector Type - Hose barb, Flat or V-Flange

 Coolant Connector Size & Type

Diameter - Sized to Suit Application
Connector Type - AN/ORB, BSP/BSPT and NPT threads, JIC, Wiggins

 Coolant Port Orientation

Configurable

 Configure Barrel Intercooler

Get the Barrel Intercooler Performance Data

Access indicative performance curves, representative boundary conditions, key specifications, and validation context for the Conflux Barrel Intercooler range.

The Conflux Core™ inside every water-to-air barrel intercooler

At the centre of each Conflux Barrel Intercooler is the Conflux Core™ – an additively manufactured internal geometry with optimised flow paths and ultra-thin fins. The core is engineered to deliver strong heat transfer in a compact water-to-air barrel intercooler package while managing system pressure drop for high-output engines in tight bays.

Thermal effectiveness for water-to-air charge-air cooling

The Conflux Core™ geometry is designed for high thermal effectiveness across relevant air mass flow ranges in demanding charge‑air cooling applications. Ultra‑thin fins and optimised flow paths maximise heat transfer inside the barrel intercooler without requiring a larger or less packaging‑friendly unit.

 Controlled pressure drop to sustain boost

Fin density and internal channels are tuned so the water‑to‑air barrel intercooler manages pressure drop rather than sacrificing boost and response. By balancing heat rejection and pressure management, the core supports higher power levels and stable charge‑air pressure under representative boundary conditions.

 Compact barrel architecture for constrained engine bays

The Conflux Core™ enables a compact barrel intercooler architecture that integrates cleanly into modern, space‑limited engine compartments. Barrel format and core layout support flexible routing of water‑to‑air circuits, helping reduce frontal‑area and packaging trade‑offs versus conventional air‑to‑air or brick‑style WCAC solutions.

Trusted by

Conflux is proud to work with industry leaders including:

Case Study

Donkervoort P24 RS: Barrel WCAC for a 600 hp, 780 kg Hypercar

Learn more Donkervoort P24 RS: Barrel WCAC for a 600 hp, 780 kg Hypercar

Ready to spec a Conflux Barrel Intercooler?

Whether you are selecting a production-ready model or need a configured solution, our team can help you qualify the right path.

Enquire Now