Aftercooler with tube and fin design

An aftercooler for cooling a charge air of an internal combustion engine, the aftercooler comprising:

• a first side sheet;
• a first header plate;
• and
• a core assembly positioned adjacent the first header plate and the first side sheet, the core assembly comprising:
• a plurality of tubes coupled to the first header plate;
• and
• a plurality of rows of fins coupled to the plurality of tubes, wherein a first fin of the plurality of rows of fins coupled to at least a first tube of the plurality of tubes closest to the first side sheet has a first distance from the first header plate of between 25 mm and 75 mm, inclusive.

A method of assembling an aftercooler of an internal combustion engine comprising:

• providing a first header plate and a first side sheet;
• coupling a plurality of tubes to the first header plate;
• coupling at least a first tube of the plurality of tubes to a first plurality of fins while leaving the at least the first tube exposed and free of the first plurality of fins for a first distance from the header plate;
• coupling a second number of the plurality of tubes to a second plurality of fins while leaving the second number of the plurality of tubes exposed and free of the second plurality of fins for a second distance from the header plate, wherein the second distance is less than the first distance;
• and
• positioning the at least the first tube of the plurality of tubes to be a most adjacent of the plurality of tubes to the first side sheet.