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Old 12-26-2012, 02:41 PM   #1
Thor4SL2
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Default Phenolic Heat Shields

Some time ago the guys at SDA (now out of business) had phenolic spacers made to fit between the intake manifold and the cylinder head for Saturn twin cam engines. The purpose of the heat shield is to insulate the intake manifold from the high temperature of the cylinder head resulting in a cooler temperature of the incoming air. This is beneficial to all applications but particularly to turbo charged engines. If you are running a cold air intake you need this, a hot manifold simpaly re-heats the air without a heat shield.

Unfortunately these have not been available for quite a while and it seems unlikely they will be making them any time soon. With this in mind I decided to try fabricating some. . I used G-10 fiberglass reinforce epoxy, 3/8Ē for the cylinder head spacer and ľĒ for the throttle body spacer. These will work on any 91-98 S-series DOHC head with an aluminum intake manifold. They install just like replacing your gaskets.

http://www.chargerforums.com/forums/...ad.php?t=33559

http://sharkracing.com/acecart/bin/s...cate=011003000

http://www.outlawengineering.com/hondajframe.html

Unlike many buy-ins, these are done and ready to ship. The price is $75.00 shipped in the US and $80.00 for Canadian shipping.

Send questions to me at rraffurty@zoomtown.com Also my Pay-Pal address.
Attached Images
File Type: jpg Copy of Saturn heat shield 001.jpg (61.5 KB, 41 views)
File Type: jpg Copy of Motor Mounts & Brackets 025.jpg (129.3 KB, 36 views)
File Type: jpg Copy of Installing Heat Shield 003.jpg (111.0 KB, 34 views)
File Type: jpg Copy of Installing Heat Shield 005.jpg (71.6 KB, 34 views)
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Old 12-26-2012, 11:12 PM   #2
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Default Re: Phenolic Heat Shields

very neat idea been thinking of this for quite some time myself already have the material just need to trace the gasket and cut it out with a dremel. Price for me is a bit to high considering the cost of the material isnt bad and how easy it is to do. But for those tht dont want to wait this is a great idea. The Tb is basically a waste if your already doing the intake though, but if not then the Tb would help by itself. I myself am using G-10 black Garolite for mine also 3/8s thick but with tht will need to have longer studs for the intake manny not much left on it with this added.
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Last edited by SC2-0220; 12-26-2012 at 11:22 PM.
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Old 12-28-2012, 03:02 PM   #3
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Default Re: Phenolic Heat Shields

Quote:
Originally Posted by SC2-0220 View Post
very neat idea been thinking of this for quite some time myself already have the material just need to trace the gasket and cut it out with a dremel. Price for me is a bit to high considering the cost of the material isnt bad and how easy it is to do. But for those tht dont want to wait this is a great idea. The Tb is basically a waste if your already doing the intake though, but if not then the Tb would help by itself. I myself am using G-10 black Garolite for mine also 3/8s thick but with tht will need to have longer studs for the intake manny not much left on it with this added.
You must have a pretty good source for phenolic a piece of 3/8Ē 12x24 black costs me $154.00 + shipping.

The throttle body spacer is not as important as the manifold spacer but there is a heat source just next to the throttle body so every little bit helps.

You donít necessarily need longer studs. I recommend replacing the studs with M8-1.25 x 40 hex bolts or cap screws w/ washer.
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Old 12-29-2012, 01:23 AM   #4
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Default Re: Phenolic Heat Shields

I've seen some in depth data from some of the stock car engine builder types on phenolic spacers, and the general consensus seems to be that the changer in intake manifold runner length have just as much, if not more, effect on the power band and power production. Likewise has been proven true with some of the "tornado" type gadgets, where the actual reduction in flow favors power at a certain (lower in this case) rev range.

I'll see if I can dig up the data on the phenolics though, probably still have a link somewhere. But with the velocity of air traveling through the intake, the temp drop in NA cars was very minimal. One guy did some data points and determined that just ducting a small amount of air to the exterior of the intake lowered temps just as much. In combo you could get larger temp drops, especially if you did something to keep it from heat soaking from the radiant heat. If you look at some of the earlier Celica's they had a scoop which actually cooled the exhaust, due to the exhaust exiting at the rear of the engine.

As for price, they have never been cheap. I think you'll need some good bulk in your purchases to get the prices down. Back in my sign making days some of the local specialty plastics/acrylics suppliers sold several types, and the prices would almost make you pass out.

Do your homework as well. Some phenolics have specific heat ranges at which they are more efficient, and some have broader heat ranges at which they work well. Also keep in mind that the heat still exists, and if it's not heat soaking the manifold it's remaining in the head.
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Old 12-29-2012, 01:00 PM   #5
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Default Re: Phenolic Heat Shields

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I've seen some in depth data from some of the stock car engine builder types on phenolic spacers, and the general consensus seems to be that the changer in intake manifold runner length have just as much, if not more, effect on the power band and power production.
Good point. Lengthening the intake runner does have a beneficial effect in our Saturns. This shifts the peak torque & horsepower down the RPM range. This is a good thing since the Sx-2 engine peaks very high up.

Quote:
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...with the velocity of air traveling through the intake, the temp drop in NA cars was very minimal..
The links I provided show a substantial drop in manifold temperature, how much cooler the incoming air is I do not know but their dino results showed a marked improvement in HP & torque. Some years ago a carburetor manufacturer actually made a carburetor out of phenolic to take advantage of this. I believe it was called the Thermo-Quad.


Quote:
Originally Posted by Signmaster View Post
One guy did some data points and determined that just ducting a small amount of air to the exterior of the intake lowered temps just as much. In combo you could get larger temp drops, especially if you did something to keep it from heat soaking from the radiant heat.
I made the heat shield as large as possible for just that reason, to block some of the radiant heat from the head.


Quote:
Originally Posted by Signmaster View Post
...keep in mind that the heat still exists, and if it's not heat soaking the manifold it's remaining in the head..
Not exactly. The heat still exists but it is quickly disbursed by the carís cooling system. What I have found, after almost a year of driving my SC-2 with the shield installed, is that the car actually reaches operating temperature (thermostat opening) a bit quicker. Once the thermostat is open the temp stabilizes at its normal range. This includes many hot summer, stuck in construction, 5-MPH traffic on I-75 days without any overheating. If properly maintained the Saturnís cooling system is more than adequate, since the intake manifold is not a major heat disperser compared to the radiator and the exhaust manifold.
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Old 12-29-2012, 03:03 PM   #6
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Default Re: Phenolic Heat Shields

I used to machine carb spacers out of Benelex, now gone but replaced. http://www.complast.com/benelex.htm They work as advertised.

This may actually be beneficial for the daily driver as moving the peak torque/power to a lower RPM would help overall real world efficiency.
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Old 12-31-2012, 04:00 PM   #7
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Default Re: Phenolic Heat Shields

OK so we have kicked this around for a while. The links I provided show actual results, not on a Saturn, but valid just the same. The point of starting this is that I made up 4 extra ones. The cost of the materials (buying a full sheet) and the time designing, setting up & machining them didnít justify making just 1 or 2. So, who wantís one? Remember I will not be making any more, itís too difficult to work with this stuff and yes they are made in the USA.
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Old 01-02-2013, 01:17 PM   #8
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Default Re: Phenolic Heat Shields

Thanks OldNuc, yours are on the way. Only 3 left, don't wait.

By the way, the throttle body spacer is designed to fit a Geo throttle body and includes 2 gaskets. Anyone running the stock Saturn throttle body can cut it down to fit. Thanks.
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Old 01-03-2013, 12:17 AM   #9
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Default Re: Phenolic Heat Shields

Quote:
Originally Posted by Thor4SL2 View Post
Thanks OldNuc, yours are on the way. Only 3 left, don't wait.

By the way, the throttle body spacer is designed to fit a Geo throttle body and includes 2 gaskets. Anyone running the stock Saturn throttle body can cut it down to fit. Thanks.
how much?
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Old 01-03-2013, 03:23 PM   #10
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Default Re: Phenolic Heat Shields

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how much?
As the first post says $75.00 shipped to US.
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Old 01-04-2013, 01:23 AM   #11
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Default Re: Phenolic Heat Shields

I'm sold, I have to wait till after 2pm on jan 11 to PayPal you due to a recent bank change is that okay?
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Old 01-04-2013, 02:13 PM   #12
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Default Re: Phenolic Heat Shields

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I'm sold, I have to wait till after 2pm on jan 11 to PayPal you due to a recent bank change is that okay?
No problem, I'll set one aside for you.
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