looks like a great find! I'll post pics of my ghetto fabulousness when I find my camera battery charger.

 

I bet that top hole was a welded on mounting stud. Probably mounted by it... vibrated the welds and it cracked off.

Keep an eye on that hole once you get the setup on. Unsure how well that epoxy stuff will seal and hold up to the pressure/vibration/etc...

 

Yeah, id check that patch a few times after you get it up and running...

 

I'd cut a piece of aluminum, and do the same on with that on top of the seal. If it can hold a radiator with 13-16psi and 200* or so, it should prove to hold an intercooler at the same.

 

If your bar/plate intercooler is anything like the one I installed in my dad's car, then that hole does not go thru to the cross tubes. It is there for a mount that should have been included with the intercooler.

From the pic it looks like it was fine the way it was. Those two bright vertical lines inside the hole are the external cooling fins. The top row of fins are hidden by the plate with the hole in it.

Did you try covering one hole with your hand and blowing in the other? Kinda a silly question...

 

yea I think it didnt go thrue the crosstubes ...but in any case the intercooler alone is what I GOT for 45 bucks....but for any assurance I sealed of the the hole for now....after intial install it most likly be wise the weld over that spot. im not sure though

 

My bar and plate I/C is the same, a hole in the first plate of Al won't leak.

 

Should help keep things steady at 8psi of boost, And help keep knock away, when I install my emanage in feb Im going the make adjustments on timing when the turbo is installed, Im going to try to get everything done by the end of feb, would I by chance need to buy a second timing retard device, like maybe the sebring unit that miatamania or fm sells?

 

YUP! - Ever heard a cork come out of the Champagne Bottle?
I would think that it would not be too much money to have someone TIG weld a little square of aluminium on there the same gauge thickness!

 

+1...and the car looks SO much cleaner....so does a paint job but we aren't perfect