My car is an 08 with an HP tune at 20psi, ZZP catless downpipe, and a K+N drop in filter. The car has been tuned for 27k miles with zero problems up until now.

I was visiting my grandmom on friday night and as I was pulling out of the gas station I went half throttle in 2nd gear. When it hit alittle over 10psi the intercooler opened up with a loud bang and a backfire out the exhaust. The car actually drove somewhat fine and I made it home without any problems. I was expecting the problem to be charge piping related but to my suprise it wasn't.





I'm glad it happened on a Friday as it gave me the weekend to get the car back up and running. After removing the intercooler I deemed it somewhat fixable and bought some JB weld. This is my rig up just to get the car driveable this week and no I'm not expecting it to hold up under boost.



This is what I have coming minus the BOV as i'm using the stock bypass.



Believe it or not I was actually content with the Cobalt and the power it was making. Buying an intercooler wasn't even on my mind but since this stocker blew open now is the perfect time to upgrade

Andrew

 

haha that sucks and on a 20psi? thats crazy is that the treadstone ic btw?

 

its ZZP

 

suck that happened but at lest you picked some good parts ZZP

 

oh ok nice and yea at least you got a upgrade just sucks how you got it lol

 

Yeah it's ZZP. I was impressed with their downpipe quality so they were my first choice for the intercooler and charge piping.

 

unfortunate. Let us know if the jb weld works. It could be a good temporary fix for any of us that have problems with ours down the road.

 

If the intercooler comes in this week i'll test the JB weld this Friday night LOL. If it holds i'll consider it a backup intercooler. If not i'll laugh and limp the car home.

 

This picture explains why it was splitting. You've been hitting it against stuff.



I've said it many times. Pull the condensation bar and fill the holes. The intercooler will not crack if you're running stock charge piping (with the recall fix), and do not hit things. Pulling the condensation bar is one of the best ways to ensure you don't hit the bottom of the intercooler.

 

I hit the intercooler on the ground one time within the first 2 months of owning it. This happened 2 years later.

 

im sure u can warranty that, i know for me it would be

 

I've seen this twice once when a friend accidently scraped leaving a gas station and put a hole in it dealer installed a Modern Performance one for him since it would take them awhile to get a stock and they still covered it all under warranty. And a buddies Solstice, had a nice crack in it after a night at the track.

 

That sucks. Nice work with the JB weld. That stuff is magic. I was offroading with some buddies back in the day and we used some to keep a radiator bracket kinda held together with some duct tape, bailing wire and jb weld. It only had to last 8 miles.

Let us know how well it holds boost when you test it out. I say start over/under betting at 12psi... I'll take the over.

 

lol the same thing happen to me except im on 23psi

 

I think it needs a bigger band aid.....

 

If this happen to me, my ass would be at the dealer the next day cussin up a storm!!!

 

well it wouldnt be the dealers fault theyd prob say tought **** lol your tuned buddy!

 

True, I woulda had my **** tuned back to stock then taken it and proceeded with the storm

 

Dude you gotta pay to play. If you brake something because of a tune or a mod then don't make chevy pay. Its not their problem... Use it as an opportunity to upgrade with a better built aftermarket piece. That being said 20psi isn't that high since a GMS1 runs a few more psi then that.

I like the route slowstang took... Nicer aftermarket part that will add to the performance of the motor. Sometimes the General doesn't always issue the best stuff from the factory.

 

haha yup exactly

 

I agree with you gotta pay to play. It's not gm's fault that i'm running the intercooler well past the target boost level.

 

As tough as it cured i'm willing to bet over 12psi...actually i'll say that it will hold whatever I throw at it.

 

Yea but the GMS1 hits up to 22psi on a stock intercooler. I say toss up on the warranty work. If you had the GMS1 they would literally have to fix it. So l would say that its not your fault per say but it is an excuse to get a better part.

 

i know a few people that work in the shop and in service as in service advisor im good to go trust me lol

 

I've ran a welding tip in the past and would see 30psi on a 3rd gear lug. But we're only talking a few psi difference. My car having the previous damage on the intercooler plus aftermarket mods I didn't even bother.