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T.Alan Kraus T.Alan Kraus is offline
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Default more threads or bigger diameter?

Lets see: a 1/4-20 stainless bolt has a max of 1300 lb/f of clamping
force. Shear is about 60% of that, and you plan on using 4 bolts. So
four bolts will resist a maximum shear of 3120 lb/f if torqued to about
65 inch/lb (note inch not foot). The intercooler produces a shear force
of 30 lbs at 1 G, at 10 Gs its 300, at 100 Gs its 3000. The question is
whether it will ever experience 100 Gs.

cheers
T.Alan