Phenolic Intercooler for your Gen3/Gen5 M90, L67/L32 3800's - LOOK INSIDE

Yes I had to shave down my intercooler corner by half an inch and my alternator housing

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One gen 5
One gen 3
And 2 throttle body adapters ready to go.

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Milled down a gen 5 LIM and supercharger. Extra 1/4 inch of clearance.

I thought this wasn't needed with the new core design.

New core is 2-1/4. Just playing around to see how much hood clearance I can get.

I don't think anyone has ever reduce supercharger and LIM thickness.

OH! I actually didn't even realize you milled down the whole thing! SWEEET!

I was talking about the H bar.

i know many asked you the same question and i asked you many questions but i have read the 5 first page and here are my questions about the older version you wrote that you can fabricate the older version so i want the older because its 2 inch thick and for fiero Hood clearance i want this version .the questions is for the gen v ( older ic )
1. someone asked you if it can fit on a zzp machined lim and you said that the core size cannot have the pcv port but on the revised zzp can it fit and drill a hole for the pcv ?????? i asked that because i want a ported intake runner with my lim and i dont see that you made these lim with ported intake runner
2. can i use a garlock sc gasket and trim it to fit the ic you made or can i fabricate a gasket that will fit your ic with a zzp lim ????i know you recommend rtv sealant but want to try a gasket and will check for leaks ( i dont like rtv )
3. last questions if i can fit a zzp lim what is the version i will need revised or not ???? breather or not ?????? thanks a lot very confusing question i hope you will understand the questions thanks a lot

1). You can use on zzp manifold. Use gen 5 with gen 5 supercharger there rear hole may line up with my PCV rear hole. You will have to check it. There tiny groove will not work on my intercooler so you will have to connect front valve cover to TB yo get proper PCV.

2). I only recommend RTV! Don't wast your time!

3) use gen 5 lim with gen 5 supercharger for best air flow.

Your work is really fascinating and cool. I am very interested in how that milled genv and lim turns out. Does everything still line up properly?

I am still trying to figure out a way to get a tiny bit more clearance with my SD hood. Currently it takes more force than i'd prefer to close it, and there are two spots on the supercharger that are hitting the hood and wearing down on both the charger and the hood. Debating on just grinding those spots down a little bit on the supercharger and then repainting I guess. I tried adding a few washers to the hood but that didn't help really, and I don't want to gain gaps on the outside.

I cant figure out why this phenolic stuff isn't used for more. I mean I could grill a steak on my genV with my SSIC and now I can leave my hand on it comfortably at any time. And I am loving having functional PCV.

If I understand phenolic correctly, it literally just has practically zero heat transfer properties right? Why not somehow apply this theory to the intake somehow. I mean one of the main reason cold air intakes are so ineffective on our cars is because even if you insulate the box significantly it still gets heated by the crossover as it makes it way to the throttle body and sc. Would it be theoretically possible to build like a phenolic box and some kind of phenolic tube that could go over the exisiting piping and throttle body or something? or even just some kind of blocker plate over the headers/crossover or something. I know you can wrap headers and ceramic coat them, but I have wrapped ceramic coated headers and it still doesn't make much difference.

Maybe those ideas are too complex for the properties of crafting phenolic material or just too expensive, but if it really does block heat that well it makes me wonder if it cant have vastly greater possibilities.

My intake temps (before supercharger), are always well over 100F with my mod level during daily driving and id like to find an alternative...

Working on the Milled gen 5 install. Will have more info soon.

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Are you still running the egr with your intercooler install?

Yes. I still run EGR.

Is there any credence that running the egr with an intercooler will gum it up and not make it as effective to cool the air?

Yes. But PCV, EGR and just the intake air will also put some stuff on the heat exchanger.

I've had mine off a couple times and I didn't think it was excessive being on there for 3 years.

On the plus side the build up also builds on the rotors making the supercharger more efficient.

Have you noticed any gains after you switched to the new style core?

My new car is not modified to the extent as my old car. That said, the new bigger core has more cooling!

Will the notch for the larger alternator case clearance (post #461 and #462) be incorporated in the final design for the Gen V or will this need to be a special request?

Quote:

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Originally Posted by buford1972

Will the notch for the larger alternator case clearance (post #461 and #462) be incorporated in the final design for the Gen V or will this need to be a special request?

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All will be notched from now on.


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Gen 5 to L67 throttle body adapters available $80 shipped with bolt and gasket.

One gen 5 intercooler available.
One gen 3 imtercooler available.