... I was considering the Killer Chiller but this seems much less work since I already have the HE in place.
The Killer Chiller rocks! But it is quite a bit of work to install it. Just depends on the level of cooling you want for your IAT2. With my Chiller, after some hard runs, I have yet to measure coolant temps above 72* in the reservoir and the outer skin of the intercooler itself using a laser thermometer. And that's on a 90+* day. So imagine how cool the IAT2 is. There is a drastic difference in power between having the unit "activated" and not. (It's not really "activated" since it's a passive cooler that uses your AC system to work.)
Is the stock pump sufficient for the triple pass?
It should be since it's not pumping fluid up any vertical length worth noting. You'd have to have either a very restrictive passageway or a gargantuan HE for the stock pump to not move the coolant fast enough.
On the units with the fans, they are wired to always turn on with the intercooler pump, right?
What happens when you are moving at high speed, say 80mph+? Could the fans become more of a restriction at high speeds than not having them on? Imagine a long top speed run, I don't think I'd want the fans running at anything over 80mph. Just wondering about that, read that somewhere.
I had this discussion with Van a couple years ago. The fans will free-spin at speed. As long as the air flowing through the fans doesn't push them past their max RPM, there shouldn't be any restriction worth noting. If the fans get to a point where they simply can't spin any faster, that's when you have a restriction. No idea how fast you'd have to be going, though.