wow that is a sick project!!! im lovin it!!

The turbo is officially part of the powertrain! All I need to do is finish the downpipe, run the oil feed line and oil return line. The K&N filter has already been ordered.

I made the lower plate for the */c intercooler. I am going low-tech... hard maplewood was used. Excellent heat isolation, no gaskets needed. The total thickness will be 2-3/4". I already measured and it will clear the hood nicely. I won't be able to use the engine cover, though (darn!)

Next, I am building the turbo intercooler. I was going to use a front mount intercooler (fmic), but I have decided to go all-out and build a much smaller, much more efficient liquid-air unit. It will go right under the turbo where the charcoal canister is, behind the front bumper. Total charge-air piping will only be about 3 ft, instead of about 10ft with a fmic.

Gotta take a few days off to finish some other things, but I'll be back on it next week.

now thats high tech wood intercooler

what is that core from for your wood intercooler?

Nice progress! I like the recirculated wastegate and intercooler below where the charcoal canister goes idea.

It'* a Probe heater core.

People have been using wood carburetor spacers as heat insulators for decades. My only concern is the core is quite a bit wider than the intake opening. I'll actually be squeezing the core a little and using it to help keep the spacers against the intake and supercharger. Once it is under pressure, there will be no worry about leaks. As it heats up and dries out, I might need to re-tighten the bolts a few times. After that, it should be fine. If it doesn't work out, I make a new set of plates out of a phenolic material I found. It'* a little pricey, about 250.00 in materials, but cheaper than aluminum!

i have heard of using wood before for a intercooler? Do you have any concerns about warpage and condensation causng any weakness in the wood.

That'* because I think outside the box. Also, unlike most people in the 3800 community, I have been building fast cars for 23 years. The hardwood is an old-school mod. Will it seal? Yes. How long will it seal? I don't know. Will it warp? I don't know. I do know that it will keep the blower cool. The wood is kiln dried, so it has only about a 3% moisture content. Once it has run a while on top of the intake, I'm sure it will dry out more. If you think about it, the actual contact area is rather small (look at a L67 intake). I will probably use two gaskets, though I think it wood seal without them (pun intended).

Of course some of us more "seasoned" folks have heard of wood being used to heat isolate carbs and other parts. Also, as an ex custom woodworker I can say that hard or "rock" maple as it'* sometimes called is about your bets bet. It is extremely stable due to it'* close grain and consistent density throughout.

Your project is exciting and is a good shot in the arm for some of us. I'm enjoying it.

LOL! SEASONED! Too funny...


Ya, that'* why I chose the maple. Plus it'* not as expensive as some of the other hard woods.

Thanks! I thought the BC forum was a little sleepy when I first came here, so I thought I'd wake it up! LOL!!!!