Start at Post 551 for current design pictures. Hybrid phenolic Intercooler with working PCV.
November 2015
Current price is $495 with bolts and shipping (Flat Rate USA)
http://www.grandprixforums.net/showpost.php?p=1325093
Originally Posted by sseilmnop
Machining 1 video by sseilmnop - Photobucket
Machining 2 video by sseilmnop - Photobucket
CNC Phenolic Intercooler 2.02 inches thick. Phenolic material does not transfer the engine heat to the supercharger!!! Works with Eaton M90 superchargers Gen 3 and Gen 5 available. EGR is functional but the PCV will need a machined manifold (1/4" hole drilled) and an air breather. Note I connected a fitting on my oil cap to the N* throttle body to make my PCV fully functional without an air breather.
See this link on how to get you PCV fully functional
PCV
This unit is approximately 3/8" THINNER than the ZZP phenolic intercooler. This unit will fit under most stock hoods without cutting the hood, using cradle spacers or using an ZZP inlet turndown (only about 70mm ID). An intercooler 2-3/8 will hit some stock hoods. I didn't use gaskets, I used Permatex to seal the Intercooler to manifold, intercooler plates and the intercooler to supercharger. I recommend Permatex Ultra Grey Rigid High-Torque for it's adhesive properties but it is not included!
Core is aluminum construction; 34 fins per inch, 18 water channels and 5/8 diameter connections. Core is 1/4" thinner than ZZP's but they have only 28 fins per inch and 16 water channels.
I have made more than 50 of these intercoolers. The first one I installed June 2010 on my Bonneville daily driver.
January 2014 still running 1st intercooler.
Machined manifolds have the inlet opening increased for best air flow with intercooler, throttle body coolant passages are plugged, coolant flow is increased from the rear head and manifold is shot blasted.
PRJ aluminum intercooler, 2.125 thick, looks cool but they are preorder only, takes months, and expensive. $925 plus manifold.
ZZP Phenolic intercooler, 2.375 thick, is $850 plus $100 for the manifold. (no longer available December 2011)
ZZP Aluminum intercooler, 2.25 thick, is $$650 plus $100 for the manifold
WBS Aluminum intercooler(PCV functional with air breather), 2.25 thick, is $550.00 plus $100 for the manifold
Reference
PRJ PRJ
ZZP ZZP
WBodyStore W Body Store
Gen 3 intercooler w/bolts and shipping $549(total price)
Gen 5 intercooler w/bolts and shipping $554(total price)
Machined Manifold $150 no core charge (shipping included w/ intercooler purchase)
Shipping, USPS (lower 48 states)
Canada add $25 for shipping
Gen 5 bolts (Zinc plated and 1 long bolt is black)
Gen 3 bolts (Zinc plated)
You pay PayPal 3% or friend / family transfer.
I DO NOT have complete kits, I just have intercooler cores, machined manifolds and bolts. Here is a list of what else is needed along with links of where to get it.
- W Body Store Fuel Rails $179.00 plus $20.00 core (free shipping)
W Body Store- W Body Intercooler install kit. $329.00 (free shipping)
Includes pump, front mount heater exchanger, hose and fittings
W Body Store- Dorman - Autograde Heater Hose Connector, Plastic, Size - 5/8" x 3/4 (includes 3) $5.95
Dorman 500-011 - Dorman Fittings & Plugs - Overview - SummitRacing.com- Dayco 87000 - Dayco Molded Heater Hoses (2 required) $6.50/each
Dayco 87000 - Dayco Molded Heater Hoses - Overview - SummitRacing.com- Loctite 37464 - Loctite RTV Gray Silicone Gasket Maker $5.99
Loctite 37464 - Loctite RTV Gray Silicone Gasket Maker - Overview - SummitRacing.com
I'm also on 3800 PRO (SSEILMNOP)
My Email / Paypal
sseilmnop@gmail.com
Installation informationManifold Recommendations (already done if purchased manifold)
1. For best air flow, the lower manifold inlet opening should be machined to match the intercooler. You will also need to drill a hole as shown in the picture. Place the lower phenolic plate on the manifold for proper positioning.
2. I recommend sealing the throttle body water passages, sanding the diameter of 2 dimes, and sealing with RTV works well. NPT pipe plugs also work.
Installation and RTV
1. All surfaces should be degreased and dry. A coarse surface is better for RTV to adhere to.
2. Intercooler plates do not come sealed, they should be sealed with Permatex Ultra Grey Gasket Maker (RTV). Put RTV around both tube connections and on the flat surface between the plates.
3. I recommend sealing the phenolic intercooler to the lower intake manifold and to the supercharger with RTV, no gaskets.
4. Put 4 small dots of RTV on the heat exchanger corners, top and bottom to prevent any rattle or movement, do not over do it.
5. Make sure that the drilled hole shown in the picture is not blocked with RTV, a short blast of compressed air through intercooler matching holes works well. This is your rear PCV port. This supplies vacuum to your crankcase. Valve cover breather is required for the front port which does not fit on the intercooler. Also see the link below. http://www.grandprixforums.net/how-g...her-44478.html
6. RTV needs time to seal, do not start engine until it has had time to cure!
7. I do an initial torque and then do a final torque once it has cured.
8. Clearance is very tight to the pulleys and brackets, I used 5/8” molded heater hoses shown, available at most auto parts Stores. Trimming of one tube may be necessary. Google “molded heater hose 5/8” and you will get results from $2 and up.
9. Contact me with any questions…. sseilmnop@gmail.com
4/29/2012 (4) ready to ship
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They are made from phenolic and break at 8 ton.
Well above the 1 ton needed.
Cost is $86 including USPS FLATE RATE SHIPPING to most USA.
You pay PayPal 3% or friend family transfer.
