I would think the bigger cooler would be better, less restriction and cooler air. Less hp to turn the blower, able to run more boost.

Never too big, just like never too much HP. I will take a stab at his but based on tom's response to my question above, I wiould say once you get a big enought intercooler where you get a cooling effectiveness of 90% you do not need to go any bigger.

any prochargercooler could never be too big,think of it this way,a m-3 pumps 2200 cubic feet per minute of air,a "big" inercooler might be 2 cubic feet instead of 1.5cu ft,Smitty

I agree, I think it would be a practical impossibilty for most of us to find space to fit too big an inetrcooler in our boats anyhow.

BTW: Here's a trick I thought of trying for like a kilo-run type race.
Take a large ice-chest (one that can fit somewhere in your boat, not too far away from your engine - single engine cats like mine have plenty of space on the sides of the engine compartment) and secure it to the floor and put like an AN -8 or -10 bulkhead fitting in the bottom and connect to a high volume fuel (or water) pump and run that through your intercooler. You can either dump the water overboard if you have a big enough volume of water for a run or you can dump it back into the chest ("cooler/tank"?) Fill the chest with ice and water (or dry-ice/ alcohol?) right before the run and you have a simple home-made "supercooler" for the occassional top-end blast. Obviously, it wouldn't be wise to run around with it all day until the water heats up but it should work for a run or two (or just keep refilling it with ice and water).
I would recommend that you put some sort of screen over the fitting inside the chest to keep a block of ice from clogging the flow.
Whenever I get my boat back together, I'm going to try this and report back on it. If someone else tries it first, I'd like to know if it makes a difference.

I seen this done exactly with a m-1 procharger a guy bought of e-bay that had a marine innercooler that he ran in a car. He used a circ pump like a schoolbus uses for the rear heater and mounted the cooler in his trunk.Never seen it work yet as he has never got carb right but seems like a good idea,Smitty

I can't take credit for the invention of it. I actually recall seeing an article with a Dodge Dakota Pickup with a Vortech kit that had a similar setup sitting in the bed of the truck, and from memory according to the article, it worked well but I can't recall any numbers.
I'll bet most if not all of those big, bad drag race centrifugal blower motors use the same sort of thing to generate the really big numbers (and small ET's).
Smitty: I'm wondering if the system worked so good that it threw the jetting off? Or did he have carb problems before then? I mean, if you have optimum jetting already and you add something that makes the air charge denser, you're gonna need to step up on the jetting. (As if jetting a Procharger carb setup wasn't trouble enough to begin with!)

What about cooling the air before it enters the Procharger.(in addition to after) I can take my old intercooler and cut open one side and use it in place of my K&N air cleaner. I have the room so i think i will try it. Is there anybody that sells intercoolers other than Procharger? I wish R-Tech had a system for my 496.

I was thinking that maybe a small whiff of nitrous would help cool that intake charge down too!!!
Seriously, the best place for the inter-cooler (actually it's an after-cooler that we're talking about) is downstream from the blower since the blower will heat up the air by the process of compression. If your 496 kit is intercooled (aren't they all?) then you could use the same type of thing. Another option is to route the water inlet hose going to the intercooler through some type of "cool can" filled with ice to cool the water down before it goes into the intercooler. I don't know whether this would make much of a difference though unless the cool can had a really good heat exchange rate. Moroso use to sell one for fuel that had a 1/2 " inlet/outlet that was supposed to be efficient, so that might work.
I wonder whether Tomcat has a prototype 496 Supercoooler in the works???
That new Raylar intake manifold for the 496 looks like it has a big enough plenum to hold one of those Whipple type intercoolers. I don't think the stock Procharger 496 intercooler works that well. That's probably the reason why they don't offer the kit with much boost (4-5lbs?). (The other reason is the hyperutectic cast pistons in the 496). You can believe that if Tom builds one, it'll work.

I just orderd a M-5 intercooler for my procharger. I thought i would take my little M-1 intercooler and put it before the procharger in addition to the larger M-5 after. I think I will see how the M-5 cooler works first. My 496 was rebuilt after putting a hole in the piston. Its now been rebuilt from top to bottom with the best of everything. 740 HP with 8lbs boost (thats why i need the bigger intercooler) I cut out the runners out of my stock intake and welded a plate at the bottom.I was thinking that the runners were to small and with boost i was told you don't need them. Is this true? You can see my motor in the photo section under custom engines (496 rebuild)