Update #2 I have found a local place that says they can custom make a heat exchanger that small in tube and fin type material....I will draw up my plans for the heat exchanger and take a pic to post them whenever I get the chance...I will get a price for the heat exchanger wed or thurs, and if they look at the schematic and say they can do it, then major hurdle number 1 will be cleared, now onto the custom CNCing of the plate....then onto the gasket fabrication and all the accessories...one step at a time....breath Ryan breath......
I will update this ASAP with pics and more info.

A custom heat exchanger will drive the price up. That'* a killer for the Series 1. It would be better to find something already available, and make your IC fit it.

I'd suggest trying to use a lower manifold/supercharger gasket for each side of the IC, they're proven, cheap and available many places for sure.

I'm going to post the dimensions for the heat exchanger on another board and see if anyone has any ideas..

I just noticed the gasket comment. What gasket fabrication? None is necessary as jason stated.

Ok not as much fabrication...I will be using 2 gaskets but will have to cut the opening out around where the heat exchanger will sit over the LIM and where the SC will sit over the heat exchanger

What kind of prices would we be looking at for these. What kind of horsepower/torque would we be gaining. Would the price/performance gain be worth it?

I am still aiming at a price at or around $500, and you would see a horsepower gain with an intercooler alone, only those of us that are experiancing KR with smaller SC pulleys will see an immediate improvement, this should allow a 92-93 SER1 L67 owner to go down to a 2.0" pulley from stock of 2.5" (and most modded ones are running 2.2"* with up to 5* KR on days) estimated boost would be around 14-16 psi which is alot higher than stock and a bit higher than the 11-12 they can run right now. 94-95 guys start out with a 2.8" pulley and most modded ones are running a 2.5" with up to 5* KR on days these guys (me included) should be able to run a 2.2-2.3" pulley on the street (with about the same 14-16 psi boost) and I am considering running a 2.0" at the track then swapping back to the 2.2-2.3" for the street. The big performance gains will be seen after the install of the smaller pulley and the increased boost. Right now I am limeted by heat which is caising KR these things do not combine for maximum horsepower or torque, the point of this mod is to reduce the intake heat so that we can gain even more. I wouldnt want to try and estimate what this mod and a smaller pulley would gain, but it would definately be worth it for all out performance. (I am aiming at the 350 hp mark for my car, but am planning on other mods too i.e. cam and rockers)

well, a step down in pulley size usually adds about 20 hp at the crank doesnt it?

update #3 priced the custom heatexchanger today....a little rich for the average SER1 owners blood but im still going to do it at least one off.....he did tell me that a group buy would bring the price down dramitically, and I am still planning on tryin to sell these things relitively cheap...but isnt it going to be cool to have the one and only intercooled SER1 SSEi, at least for a little while...if there is much interest in this then a group buy will again bring all the materials cost down, and I am not planning on selling these things at very much markup at all, am really not in this to make a profit, I just wanna see some more heavily modded SER1s out there, and if I could make enough by selling say 5 of these to make up for the time and effort (and money) spent making/designing the first one then it is fully worth it for me to do this....the one problem I think im going to run into is the lack of available SC pulleys right now...PulleyBoys is still closed, and I dont know of anyone else I can get a 2.2" from....or a 2.0" for that matter.....so all may be lost......anyone have any suggestions?

Someone send me their S1 pulley, and I'll whip up a CNC machine file (I gave my 2.55" to my boss). This can get us over the hump. Any machine ship with a CNC lathe would be able to make them.

My intent is not to detract from PB.....ultimately, he can make them cheaper than anyone, but in the meantime, they'd still be available.

PM me if you have one to volunteer for the effort, either from 92/93 or 94/95. You'll get it back when I'm done.