Thread: ZZP new 2.5 intercooler

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  1. #1 ZZP new 2.5 intercooler 
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    Anyone see the new core design zzp put out a few days ago?

    ZZP 3800 Intercooler Core Stage 2.5 - YouTube
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  3. #2 Re: ZZP new 2.5 intercooler 
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    Ordered one a couple days ago..still waiting on shipping info.

    I had had been looking at getting a stage 2 FSIC for a Gen 5 setup, but held off because I was going to try to make a SSIC for a Gen 3 that I had laying around work. Glad I waited, I’ll post up some pictures once I get my hands on it!

    Looks like it should be better than the previous versions. From an aesthetic standpoint, I like that it follows the shape of the blower.
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  4. #3 Re: ZZP new 2.5 intercooler 
    GrandPrix Junkie PurpleGuy's Avatar
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    I agree with the aesthetic part. It looks more factory to me
    2001 Regal GS, PLOG, 3" DP, 1.9's/L76 springs. 21* of timing on a 3.4"
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  5. #4 Re: ZZP new 2.5 intercooler 
    Donating Users bandook's Avatar
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    Looks pretty slick. Check out the YouTube if you haven't yet. I think it's a smaller core with higher fin density. And smaller inlet/outlet?
    Top Swapped 01 Imp
    VS (very small?) cam, SD Headers, 2.8" pulley, self ported everything, E85, AEM water/meth, Deka 60's, HPT tuned
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  6. #5 Re: ZZP new 2.5 intercooler 
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    Still no shipping, ordered 4 days ago on the 1st of Dec...
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  7. #6 Re: ZZP new 2.5 intercooler 
    GTP Level Member wowitsfast's Avatar
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    Welcomento zzp at Christmas time. Last year I ordered some 10.5 wires and silicon rad hoses I didn't get them untill the end of January

    But hey I got some extra stickers so there's that

    Sent from my SM-N920V using Tapatalk
    Last edited by wowitsfast; 12-05-2019 at 10:58 PM.
    Just a bunch of junk thrown together http://www.grandprixforums.com/membe...ht=wowitsfasts
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  8. #7 Re: ZZP new 2.5 intercooler 
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    Itís funny I saw your post about waiting for the wires last year!

    Good news however, I got a tracking number this evening. Says it will be here Monday night.

    Iíll be sure to post up pics and my first impression right away.

    Iím glad ZZP is still doing some stuff for the 3800. Itís getting harder to find stuff these days, especially anything new.
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  9. #8 Re: ZZP new 2.5 intercooler 
    GrandPrix Junkie PurpleGuy's Avatar
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    The video for anyone who wants to see it

    2001 Regal GS, PLOG, 3" DP, 1.9's/L76 springs. 21* of timing on a 3.4"
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  10. #9 Re: ZZP new 2.5 intercooler 
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    Quote Originally Posted by wowitsfast View Post
    Welcomento zzp at Christmas time. Last year I orders some 10.5 wires and silicon rad hoses I didn't get them untill the end of January

    But hey I got some extra stickers so there's that

    Sent from my SM-N920V using Tapatalk
    Ha! They messed up an.order of mine. Long story short, they said they would send me some "extras". I got one zzp sticker...
    Top Swapped 01 Imp
    VS (very small?) cam, SD Headers, 2.8" pulley, self ported everything, E85, AEM water/meth, Deka 60's, HPT tuned
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  11. #10 Re: ZZP new 2.5 intercooler 
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    Well guys, I came home this afternoon to this!



    Proceeded to open up and see what this thing really looks like.













    Brought it inside and after the kids were asleep I mocked it up on a LIM and Gen 5.





    Then came time to take this thing apart and see whatís going on inside.

    Here is the bottom portion on top of the LIM. The Gen 5 LIM and intercooler outlet line up exactly. No need to port the LIM to match the intercooler any longer. Also, all the PCV holes line up and go directly through the entire intercooler.



    Here is the core.





    Only identification I could find on the core.



    Upper intercooler section on top of the blower. Lines up perfectly with the outlet.



    So, up to this point, A+. Time to put it back together and I quickly realized the o-ring design might be more difficult to use than the old rtv design. The picture below is of the o-ring that goes completely around the core. The lower half has a groove that the o-ring sits in. The upper half does not have a grove, it compresses together. Notice the grey rtv in the corners? During assembly, Iím guessing you have to use something to hold these corners in place because once you start to compress the two halves the inlet and outlet of the core begin to push this o-ring downward and it pops out of the groove.



    I played with the o-ring for 30 minutes or so trying to get it to align and stay in place while I tightened the 6 bolts holding to two halves together. At one point I felt certain I had everything lined up, as I tightened I heard a grinding/tearing sound like a piece of dirt was between the halves. I decided to take it back apart and unfortunately the o-ring was cut right where the rtv was used to hold it in place.



    You can see the entire o-ring in this picture. I took a measurement and it appears to bean 8Ē O-ring with a 3/32Ē thickness. McMaster Carr carries them, but it made me pause and wonder if the o-ring design is really that much better than rtv. Only time will tell I guess, but I wonder if ZZP will be selling replacement o-rings.

    All in all, I have to say this is a quality piece from my initial observations. The machining is top notch. Everything is smooth and detailed. I had an old SSIC and can say the workmanship on this intercooler is multitudes better. As far as the functionality changes, I like that a machined LIM is no longer needed to make the PCV work and that the core cutout dimensions have been changed to align directly with the blower outlet and LIM inlet.

    I am in the middle of building up an E85, VS, Gen 5 build and canít wait to get this installed. Iíll provide updates regarding the o-ring situation once I get a replacement and ply around with it some.
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  13. #11 Re: ZZP new 2.5 intercooler 
    Killa Bee Scottydoggs's Avatar
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    how thick is that ic? looks over 2.25 inches.

    98 Buick Regal GS, F body brakes, Caddy STS wheels, tinted tails L36 bottom end, lightly ported heads, 1.95 roller rockers, headers, gen 5 N* 3.0 pulley, FSIC, 42 lb injectors, a BrandonHall rebuilt trans, DHP tuned and AEM water/Meth injection https://goo.gl/gpV5kW
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  14. #12 Re: ZZP new 2.5 intercooler 
    GXP Level Member GTPpower's Avatar
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    Great to see this. Someone needed to step up since Ed quit making his.
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  15. #13 Re: ZZP new 2.5 intercooler 
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    Just measured it, 2.25Ē
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  16. #14 Re: ZZP new 2.5 intercooler 
    Killa Bee Scottydoggs's Avatar
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    looks so thick in the pic. thats good it not any thicker, my gen 3 and my new gen 5 on a 2.25 core just clears the hood.

    98 Buick Regal GS, F body brakes, Caddy STS wheels, tinted tails L36 bottom end, lightly ported heads, 1.95 roller rockers, headers, gen 5 N* 3.0 pulley, FSIC, 42 lb injectors, a BrandonHall rebuilt trans, DHP tuned and AEM water/Meth injection https://goo.gl/gpV5kW
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  17. #15 Re: ZZP new 2.5 intercooler 
    GrandPrix Junkie PurpleGuy's Avatar
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    That’s a nice looking piece. Good to hear one will clear the stock hood too Scotty. This may be the next thing I get for the car
    2001 Regal GS, PLOG, 3" DP, 1.9's/L76 springs. 21* of timing on a 3.4"
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  18. #16 Re: ZZP new 2.5 intercooler 
    Killa Bee Scottydoggs's Avatar
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    the blower does touch the foam lining a bit, but not the actual hood. this is the only pic i have of the hood liner. engine 1/2 out to change the flex. but all them white spots are the rub/holes in the foam.

    Shared album - Scott R - Google Photos
    Last edited by Scottydoggs; 12-11-2019 at 10:52 AM.

    98 Buick Regal GS, F body brakes, Caddy STS wheels, tinted tails L36 bottom end, lightly ported heads, 1.95 roller rockers, headers, gen 5 N* 3.0 pulley, FSIC, 42 lb injectors, a BrandonHall rebuilt trans, DHP tuned and AEM water/Meth injection https://goo.gl/gpV5kW
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  19. #17 Re: ZZP new 2.5 intercooler 
    Donating Users bandook's Avatar
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    Nice! Thanks for the pics and good luck with the build!
    Top Swapped 01 Imp
    VS (very small?) cam, SD Headers, 2.8" pulley, self ported everything, E85, AEM water/meth, Deka 60's, HPT tuned
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  20. #18 Re: ZZP new 2.5 intercooler 
    Killa Bee Scottydoggs's Avatar
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    its done. other then getting 60 lb injectors to run a 2.8 pulley and make 15-16 psi. but id rather dump thousands into my 13 2ss/rs camaro at this point. funny but the dealership i bought it from like 7 months ago called today looking to buy it back lol NOT.

    ZZP new 2.5 intercooler-007-jpg
    ZZP new 2.5 intercooler Attached Images

    98 Buick Regal GS, F body brakes, Caddy STS wheels, tinted tails L36 bottom end, lightly ported heads, 1.95 roller rockers, headers, gen 5 N* 3.0 pulley, FSIC, 42 lb injectors, a BrandonHall rebuilt trans, DHP tuned and AEM water/Meth injection https://goo.gl/gpV5kW
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  21. #19 Re: ZZP new 2.5 intercooler 
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    Thanks for posting those pics/review for us! I have the old stage 2 currently on my car and was going to swap in either this new core or the phenolic one from Ed when I do the heads and cam.
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  22. #20 Re: ZZP new 2.5 intercooler 
    GrandPrix Junkie PurpleGuy's Avatar
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    Quote Originally Posted by GTP Mark View Post
    Thanks for posting those pics/review for us! I have the old stage 2 currently on my car and was going to swap in either this new core or the phenolic one from Ed when I do the heads and cam.
    Ed doesn't make them anymore. The core he was using was discontinued I believe. This new one looks damn nice though
    2001 Regal GS, PLOG, 3" DP, 1.9's/L76 springs. 21* of timing on a 3.4"
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