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I removed the batch panel, and to my surprise, I found the intercooler has a somewhat large dent. Everything seems to be working, but obviously this is not optimal.
Should I replace the intercooler with a "factory" used one or an aftermarket one? If there is an aftermarket performance benefit now with the car stock, as I try to increase performance, at what point is a "better" intercooler needed?
Also, what is the recommended brand if not factory?
I think your best bet would be aftermarket. I’m sure a modern intercooler would be better than 80’s technology and I’m sure a Porsche one would be outrageous unless you bought a used one.
Wow, that's one banged up intercooler. I'd start by pressure testing it to see if leaks. If it leaks, it's probably a goner. If it holds pressure, and still fits, it's still probably works nearly as well as most. I tested intercoolers many years ago with pressure and temp readings and concluded the factory intercooler is much better than people give it credit for. Unless you had a good/specific reason to do otherwise, I'd just get a good used one on eBay if that one leaks. Heat soak was the one area where big aftermarket front mount intercooler win. So if you are tracking the car for instance, and need it to shed heat asap, a bigger intercooler may pay off. For a street car with a k26 turbo, there's no real need/benefit straying from stock. I've tried several SFR intercoolers over the years and ended up removing them all for various reasons, but if you could find their stage 1.5 intercooler, that would be my choice for the best drop in aftermarket. But, of course, there's this. Several places sell the modified end tank versions, but I've never seen any verifiable gains from any of them...
Thank you, I will pressure test this and see, if bad I will replace it with a used factory unit, they are not that unreasonable in price.
Also will keeping an eye out for an SFR 1.5 on the used market, I do not want the drama of having to deal with SFR.
David Barbarian modifies the stock IC to make it flow much better. Many of us use his IC. I am not sure how to contact him. Maybe someone else here has his contact info.
I've never been fully convinced about those end-tank modifications. Anyone have any data that shows actual improvements? Assuming it creates slightly less flow restriction, does that reduce the cooling effect if the air is passing through faster? Does the new shape help or hurt flow? Help or hurt heat soak? Not saying it hurts, just saying without confirmed data it's not as obvious to me as others that it's a net improvement on a typical 951. @michaelmount123 -- ever test?
chrischrischris wrote: Fri May 08, 2026 9:02 am
I would guess the end tank modification improves performance by reducing restriction, not by improving cooling of the charge air.
Yes, that’s the theory, but it reminds me a bit of “bigger” fuel injectors. Bigger injectors can pave the way for more power, but you don’t make more power by simply installing bigger injectors -- and they can actually hurt performance unless the car is tuned for them.
The end-tank mod may be similar. If the stock end tanks already flow enough for the stock intake tract, making the intercooler flow better may offer little or no upside, while possibly trading away some cooling efficiency. The factory cast end tanks are also fairly smooth internally, whereas many modified tanks seem to gain volume by welding in flat plates that may not guide airflow as cleanly.
Now, if you also open up the rest of the intake path -- pipes, throttle body, snorkel, etc. -- that might be a different story.
I really don’t know -- just think it’s worth thinking about before accepting the mod as a sure win. Without clear before-and-after dyno results, or other solid data, I'm not anyone can say for sure.
This is very good conversation, I wonder if anyone has a done a flow test and compare these different intercoolers. The little I know about fluid dynamic and heat exchanging is that faster flow will not necessarily allow for more heat transfer because of the time the hot air spends in contact with the cooler fins.
For now, and considering that a good used factory intercooler is well under $100, I just ordered one from Elliot.
