No, I was suggesting ONLY to put a thermal insulator between the engine and the SC, and keeping the water flow the same as stock.

I'd try to kill that path and route it around. The cost and time involved is so little more to go all the way. A 1/4" spacer with intact passages, or a 1" spacer to route 2 paths.....not much difference. You MIGHT be able to pull the whole thing off in 1/2". I'll do some modelling to see what'* possible.

A 12V water pump and wrecker radiator would be the only other components needed. You don't need much flow.

Well you might want some sort of control system to keep a somewhat constant temp, although you would have to experiment to see what temp that would be.

You could probably blow air through the passages and still be cooler than the stock setup. Especially if your spacer was non-metallic. Although I prefer metal for obvious durability reasons.

You're right on track. You'd have to pick your plastic very carefully to make sure it could handle not only the heat, but the temperature cycling as well. Aluminum is the safest choice as the nearest mating surfaces are the same. You'd still have the benefit of at least 2 outlet gaskets instead of one for further isolation, although not much.

I haven't dug into it enough to see where the lower intake passages are fed from and go to, but I'm going to bet that the rear hole feeds up into the SC and TB, then back down into the forward hole, and on to the front head. Have to keep that path open.

BTW, now can everyone see why I meshed my cover and added ramair cooling?

Here you can see the yellow o-rings marking the passage locations:

Although in one of my manuals it states that the TB has coolant in it to keep it from icing, which would suggest possible problems in cold weather??

From people I know that have intercoolers, the lack of coolant in the throttle body in winter only hinders warm up and promotes icing at temperatures of -35* C and below.

Also, I added a picture of the Generation 5 M90 outlet in the first post.

Cheers,

ok why aluminum, i like the idea of using a metal, but aluminum is a big conductor of heat when compared to other metals, so why not a diffrent metal.

For the series 1 budget, aluminum is cheaper to buy and cheaper to machine. Also, since it'* the same material as the nearest surfaces on either side, thermal cycling and the leaks it can cause aren't an issue. Thermal dynamics and Coefficients of Thermal Expansion (CTE) are issues that have to be addressed. You CAN do some things to that aluminum plate to reduce heat transfer, and jwikoff and I are working on that part of the design.

ok ive been thinking if somebody were to start manufacturing an intercooler for the series 1 similar to the one for the m90 at zzperformance except with a coolant bypass like u were talking about, would it have the benefit of both?

There'* something being worked on. Read the post in Performance and Brainstorming. 2 being worked on in fact. Mine will be on the car in 2-3 weeks (currently torn down for development).