has anyone ever had a reaction to whey and it made their mucas real thick to the point of loosing their voice?
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Can't say I've ever heard of anything like this. Are you 100% sure that whey is the problem?
6'2 - 105kg (231lb)
At a guess I'd say the problem wasn't the whey itself but that you took a 100+g of a concentrated food stuff in very little liquid. If that liquid was milk it'd exacerbate the problem.
What I'm getting at is that you probably weren't too far removed from simply trying to swallow 5 scoops of powder - that'll mess with anybody's mucous membranes!
Use a lot of liquid (approx 500ml per scoop) with your protein powder if you suffer like this.