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Turbowerx includes an intercooler with the 3.2 turbo kit. Marc says he feels like he has a good factor of safety with 5 lb of boost with stock internals. Of course I don't know what sort of longevity testing their mule went through and I don't know how many of their kits have been installed.
The orginal question about NOS was driven by a curiosity about cheap horsepower. Obviously a system that is properly engineered for our engines would not be cheap relative to an off the shelf kit for a big block V8, but may still be "cheap" relative to a turbo or engine swap. I like the idea of a turbo better though because as Randall said it's always right there at your right foot. And since our cars are not about straight line power and I think a hefty shot of NOS would be tough to modulate in a curve, the turbo is more real world usable.
I was discussing this with Jay this am and I said one of the appealing things about the 3.2 is that it makes about 80% of peak torque at such a low rpm. If you went with a low compression piston to boost boost, I think you would give away low end. With a turbo, you still have stock low end with the extra forced induction power being icing on the cake.
NOS is an interesting academic exercise, but I don't think a practical app for the Box. I do still plan on going the turbo route this fall or winter, though, as finances allow.
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