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

**whoender** · 07-27-2014

My bad

Max Cook · 07-30-2014

Got mine in the mail today. Box took a massive beating but it seems to have made it alright. Looks fantastic, cant wait to get it together. Thanks

**sseilmnop** · 07-30-2014

Glad it survived. Glad I wrap the intercooler with cardboard before I put it in the flat rate box.

**sseilmnop** · 08-05-2014

Gen 3 and 5 available.

**wyoprix** · 08-05-2014

got mine im liking it put about 2,000 miles on it so far working great havent seen any KR

Max Cook · 08-13-2014

Just an fyi you may want to adjust your design slightly if possible. For it to fit in my car (2000 gp) I had to break the black plastic shroud on the alternator a little. Not a big deal but im guessing that may be adjustable in your design.

Works great though. I flipped my northstar tb and extended some wires and was able to make it fit under the cf sd hood. It is really really tight though and is rubbing a bit on the supercharger.

Also you may want to consider adding the holes for the guidepins that come out of the lim. I had to remove them and it made aligning the holes a lot harder.

Whats awesome is even after its veen running for 20 mins i can still lay my hand on the blower and its just warm. I could have cooked a steak on it when I had my ssic on there. Good stuff.

**sseilmnop** · 08-13-2014

Thanks for the feedback. I will look at the alternator clearance. Would 1/8" more clearance bye your alternator be enough?

**kurupt305** · 08-13-2014

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

**kurupt305** · 08-13-2014

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**sseilmnop** · 08-15-2014

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

**sseilmnop** · 08-15-2014

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

**Jomamma** · 08-15-2014

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

**sseilmnop** · 08-15-2014

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.

**Jomamma** · 08-15-2014

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

I was talking about the H bar.

**fierogtx** · 08-17-2014

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

**sseilmnop** · 08-17-2014

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.

Max Cook · 08-21-2014

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...