Custom Intercooler Plate Pics attatched

[minichopper6hp]

Just wondering who would be interested in this intercooler plate I made. Materials were free to me, and i was going to use it but decided to go phenolic instead, but big gains could be acheived from this. It uses a ford windstar heater core that measures 2"x7.5"x8.5", 3/4" inlet/outlet. If interested, i would have to buy a core and silicone it in and send it already sealed. This would be a great thing to someone who wants intercooled but cant afford the plate from the websites like myself. The holes are 7/16" and were drilled for 3/8" studs in the lim for more clamping force, but i suppose you wouldnt have to, but it is advised. Thanks. Any questions ask me.

url: Pictures by minichopper6hp - Photobucket

[Bio248]

how thick is the core? will it for sure close the hood?

im not interested as i want to stay non-intercooled, but just wondering.

[chrisb]

not to get off topic but where are you getting the phenolic at? i cant find any that is cheap. pm me if you want

[minichopper6hp]

Its 2.5 inches thick, i had to run spacers for the cradle 1/2" aluminum ones. I got my phenolic from ebay, 100 bucks

[chrisb]

never thought of ebay! where you pick up the core at? ive been waiting to make my own also. thanks!

[minichopper6hp]

by the core you mean the heater core right, i got it from a 95 windstar, the core is big though, but thats good. the only thing is its so large that you have to run a breather, which is no big deal.

[Clar2478]

any link for where you found it on ebay?

[minichopper6hp]

(1159)PHENOLIC CANVAS 1 1/2" THICK 11 1/2" X 37" - eBay (item 200205709993 end time Mar-01-09 11:48:49 PST)

there you go, that will be plenty enough to make your plate

[Panther427]

What is Phenolic and what are u using it for exactally

[minichopper6hp]

Its a type of composite that uses phenolic resin and a material(there are different kinds), but lets say canvas; they combine the layered canvas with the resin and compress it into a sheet. It is strong, durable, lighter than aluminum, and it doesnt conduct heat like aluminum, making it a much better candidate for an intercooler plate because it doesnt soak heat making the ic less efficient at removing heat from the air charge. Do a google search if you want to learn more about it.

[minichopper6hp]

ok, here is my work in progress, the phenolic core... uses the same ford windstar 7.5"x8.5"x2" heater core, just made out of phenolic and better, sealed design... here you go...


http://s169.photobucket.com/albums/u233/minichopper6hp/

[Bio248]

that looks really nice, i wonder how it performs.

[blueguy]

You'll have to let us know how well it goes so I dont have to spend the 1200+ on a S3PIC from ZZP

[minichopper6hp]

UPDATE:

I have finished the plate, sealed and all... pics are here

Pictures by minichopper6hp - Photobucket

the m90 mod has begun now and i will post pics as soon as i can this is going to be interesting. received the 3" mps from zzp today and will be doing the northstar tb upgrade as well...

[minichopper6hp]

is anybody intersted in buying one? i will be making them for sale and need to know if the demand is high enough. thanks.. pm me if intersted.

[Smokin2000gtp]

Damn that intercooler is sexy, it makes me wish my ic was up and running.

[speedemongtp]

what kinda price range would you even be looking at for one of these? Just curious and maybe in the not too distant future interested. Also asking for others that are probably curious as well.

[Sabrewings]

Dependent on price, I may be interested.

[minichopper6hp]

granted that i will get the materials for the price i did for this one, was thinkin $325 shipped to anywhere in u.s. As you may all know, zzps or similar is $850 so im pretty sure this would be a good deal. A couple things to keep in mind about this core... its 100 percent hand made, so im not even really making anything off of this in the fact that it takes a while to make one. Also, its not cnc machined, so dont expect it, however its still a good unit in my opinion and i will guarantee it to fit. The core is 2.5 inches thick overall, so you will probably need cradle spacers (I did) but im not going to say everyone does. The stock pcv function is no longer there but if you want i could probably incorporate it into the core so it does work ( i didnt because i dont want my new rotors all dirty again). You will need fuel rails of course, and for $40 extra i will include the heater core and have it pre-sealed, if not, just get a heater core for a 95 ford windstar and install it yourself. Im doing this as kind of a service to the gp community more than anything, because like me i know there are people out there who want an intercooler but cant afford the outrageous prices of one from the companies. There is limited amounts, and first come first serve. PM me if interested. Thanks.

[FoSHO99]

X5 dependant on price, I have a friend who is looking to IC also.

I already have a S2 IC, but your cores look amazing!!!

Edit: I just saw your price and looks like a good deal... I will talk to my friend.

Also, how do you work on these cores? Just a regular drill and tools? Is there anything that you want to stray away from using on phenolic material? If there are fitment issues or someone want to make pcv system function, it can be worked on easily right?