On the series II(of course ), Is there anything that could be done to the platic upper intake itself to increase the durability, life? I'd rather not replace it w/ a couple 1000 dollar one b/c that'* not really an option. If though about some kind of heat paint. This paint would have to be on the inside and outside to ensure that no heat gets to the plastic. But is having paint all up in there good? I doubt it. And just painting the top would trap more heat in probably.

Any ideas?

Rember the failure is caused by the hot EGR gasses passing through the plastic intake. I would not be suprised if someone comes out with a kit to cool EGR gasses down. Dont think EGR can tell how hot the air is its passing.
What shoud happen is for GM to have a class action suit filed against them and replace plastic with aluminium.

There have been a few suits about this, but they have all gone away quietly. It seems that the only years affected are 96-98. They changed to the 180 stat in 99 and after, probably due to this issue. Since it is not a "safety" issue, there won't be a recall. A few hundred thousand dollars a year to grumbling customers is part of their budget, I'm sure.