It's a rubber coupler with a "hump" in it. Typically allows the coupler to flex a little more for alignment.

 

We are looking into this. The only thing that pops out to me is that a former owner may have installed a different radiator. I have seen that cause this in the past.
I am in touch with our chief engineer. I will follow up. We have sold hundreds of these, and never had a problem, other than what I already mentioned.

 

email our CEO here: orders@halltechsystems.com

 

I really appreciate you guys looking into it. I 99.9% sure the radiator and condenser is OEM.
I have already sent an email yesterday with attached pictures that are in this thread.

Thanks again!

 

Thanks Smitty!

Update: I cut the coupling way down and got it to fit for what I believe is "the best it's going to get". I think the filter may be hitting the hood a little or if at all but it seems close. Anyways here's the fitment now.




I don't want to be the guy to leave a negative comment about Halltech but to be absolutely honest I'm not impressed. Sure the fix was me fitting, cutting, fitting more and trying to get it to work but the fact it hit my hood, my DM from Halltech, then emails to 3 different addresses and still no response is frustrating. Not to mention the filter came "wavy" on the top straight out of the box that I didn't want to mention.
I'm happy with the intake, it seems like a great idea and design but for the hefty tag that comes with it I would expect top tier quality no issues, no hiccups and no defective filter etc.
Rant over mods you can close this thread.

 

Corvette Tax is real...

This is why I went with a stock C6Z LS7 air bridge and LS7 card MAF on my C5Z...OEM fitment/quality and it performed on par if not better than my previous Halltech intake that put the filter down under the front bumper support and not very serviceable. You can find people giving away these stock LS7 air bridges that will flow plenty for a LS6 car.
​​​​​​

 

I wasn't aware that was an option however, I didn't look into going OEM. You have been a great deal of help and very much appreciate your input. I'll definitely keep that in mind!

 

You're welcome. Hope it all works out for you. There are many things that are common between C5-C7. Some take a little more tweaking to fit than others.

I had an idea to keep my car OEM+1 approach. At the time FAST 102 intakes were $900+ and the Dorman LS2 offering was ~$400. With a little porting I'm pretty sure I'm within spitting distance of an actual FAST intake. Now the Dorman intake is up to ~$900...along with a ported LS2 TB and LS7 air bridge the car is happy.

I figure the LS7 intake is on a bigger cube higher HP motor from the factory. How could it be negative for my cam/exhaust LS6 at ~400hp

 

I wasnt impressed with my Halltech either. For my race class I am not allowed to do internal engine mods so I am limited to headers and intake. I have a TPiS 90mm LS6 manifold with the Halltech Killer Bee and headers and made 394hp to the tire. Most header only cars are 385-390 so that expensive intake got me maybe 4hp? Plus the fit issues like you mentioned. I dont want to get rid of it though cause I feel like I need my money's worth, lol.

 

Pick up a LS7 air bridge for damn near free. Swap it over and re-dyno. If more or same horsepowers, sell Halltech and make money back. BOOM

 

Ill have to look into it for sure.

 

Honestly the halltech looks pretty similar to the ls7 anyway, I would be surprised if there was a big difference in power

 

I’m at 450whp with the ls7 air intake and stock filter fwiw

 

If I was to buy an aftermarket intake and the stock LS7 air bridge was not an option, I would seriously consider the C6 Airaid system or K&N. Similar design to stock LS7 intake
https://www.airaid.com/254-216-perfo...-intake-system

I think the other issue OP has is still running the stock LS6 TB. If you were running a LS2 TB you would have a simple/straight rubber coupler and most likely minimize any biding/fitment issues.

 

Another reason why this forum is so awesome!

 

Our intake does not require carving or cutting. We saw your pics, and I mentioned in this thread that we have only seen this problem where the radiator was an aftermarket larger intake, and or the motor mounts dropped the engine. Glad you got it sorted out, but neither Dru our CEO or I received any emails from you. I did talk with you by phone at the beginning of your purchase.
Pro Mechanic Hib Halverson did a report on our intake many years ago. Check it out: Z06 Killer Bee is, well....killer. - CorvetteForum - Chevrolet Corvette Forum Discussion

Do not forget to get the ecu MAF tables swapped out for the Z06 tables. The car will not start or run until those tables are corrected for the Z06 tables. HP tuners has the stock tables for the Z06, which will get you started, but you should dyno tune this setup.

This setup should yield 14 RWHP.





Thanks again for your purchase,

Jim Hall

 

I'd really like to see a back to back 3rd party dyno runs of a stock LS7 air bridge and card MAF vs many popular aftermarket intakes. Really see where the bang for the buck is.

 

Hey Jim,
I really don't want to get into a finger pointing contest but I do have sent emails to you, Dru and also to the Halltech "Orders" email that was provided in my DM with all of the pictures attached to all email addresses that was provided in this thread.
I also just received the MAF tables just yesterday but luckily my tuner did everything needed on the trailer when I did get my car tuned on the 17th.
Also I've been asked from 2, possibly 3 different people from Halltech about the radiator and like I stated in every email, on the phone and on this thread that the radiator is completely OEM and also the motor mounts. With that being said I would think IF I had aftermarket radiator or motor mounts then there would be something noted about fitment issues. If there is then I'm sorry I read over that.
Like I previously stated I don't want to start pointing fingers but kind of feel attacked as if I'm the error. Let me just say I built this motor myself over the Christmas break in 5 days from driving it in my garage then driving it on the trailer and didn't have any issues until I drove it on the trailer (on the OEM intake) and installed the cold air intake. I would assume that after doing a heads/cam car with full bolt ons making VERY close to 500whp with stock TB and LS6 intake manifold that I would know how to put a cold air intake on.
Jim, you seem like a very nice guy over the phone and don't want you to feel like I'm going after you or the Halltech name personally and I understand you guys have sold 100's of these but I feel like I did my part in being transparent as possible about my issues.
I simply started this thread to ask if anyone has had this experience with the system and if there's a remedy to fix it since I was going to the dyno and needed the intake to perform/fit correctly.
Thank you to everyone that has commented, gave advice and input options.

 

boostbandit1:

So what kind of numbers did she lay down on the dyno?

 

Appreciate you making this post. I have the same issue with fitment on my Halltech KB2 intake. I thought I was the only one..

I ended up putting a Blackwing filter in for the time being with my build with the OE air bridge. I don't know that I'm really being held back much with the Blackwing setup, but I'd like to explore options of a better fitting air bridge as my OE unit has a slightly loose fit between the bellows and the plastic bridge portion.

Anyway. I just wanted to say thanks for sharing.