When Do You Recommend Upgrading the Intercooler?
 

I have completed the reliability modifications on my car and I am slowly adding performance modifications. I do not intend to shoot for any "major" performance gains. I'll stay with the stock injectors and I'll stay less than 12 PSI boost. I am starting with a PFC to closely monitor all operating parameters.

At what point should I start considering the need to upgrade the intercooler or do I even need to consider an upgraded IC at all? I suppose that everyone would benefit from a larger IC, but when is it needed?

Are there any specific operating parameters to look for that call for a better IC such as my boost level or injector duty cycles? Intake temperature would seem to be one but I've heard it is misleading as reported by the PFC because of to the location of the sensor on the underside of the UIM results in heat soak.

I'm not expecting a definitive answer so your thoughts are appreciated.

honestly...the IC wont make all that much difference at 12psi..definately not worth the $1500.
Your best bet if you want to keep it simple is do a full exhaust, intake, power fc and run 12psi. You will make 300rwhp and run mid 12s.

An upgraded intercooler will make a difference at stock boost levels, gains of 10-20WHP are often seen. However with dp, mp, cb and intakes your car is going to need to be tuned, and much more HP and your car needs bigger fuel injectors, a bigger fuel pump and a dyno tune, even with all those mods you at least need to get dyno tuned. I have all those mods with a greddy 2 row FMIC, it made a difference I could certainly feel but afterwards I was hitting high injector duty cycles and was very anxious to get fuel mods done and get it tuned. In the Sacramento area it gets very hot, driving through there a month ago about 6:00 i couldn't go over 70 or my car would start heating up, so you would most likely need an upgraded radiator if you went with a FMIC.

i made 300rwhp with full exhast and intake with the power fc base maps...alittle more fuel down low. My experience disagrees with the 10 to 20rwhp gain at stock boost levels. There are dyno tests whioch show small gains of ~5rwhp on this forum.

A larger IC is a must upgrade, when running over stock boost levels IMO.

The most important reason to upgrade the IC from a reliability standpoint is the reduced pressure drop. When I installed my PFS smic (on the smaller side of upgrades), my boost jumped nearly 2 psi with the same setting on the boost controller. In other words, your turbos will have to run 2 psi more with the stock IC than they would with a larger IC. This becomes important to turbo longevity when you are running above stock boost levels.

Never too soon to get rid of the IC that came with the car. I think i got one like it with my Cracker Jacks once.

I would estimate that my PFS intake and IC netted my about 25 hp, to which i attributed 15 to the intake, and 10 to the cooler... not to mention cooler temps are always good for reliability... people will debate the FIC/SMIC thing ad nausium, but almnost nobody debates the need for SOMETHING besides the stocker.

Yes. Upgrading the IC at lower boost levels doesn't show much on the dyno. However, it will allow your turbos to make the same boost without working as hard and you'll have MUCH better turbo response.

After upgrading mine, even to just a "true" SMIC, I wish I had done it sooner.