This thing is rated for 1300hp... which would require about 33PSI on a bulletproof 2.4L with 116 octane. I just have a tiny little 50-trim and a measley 433chp from my 2.0L. My car is running fine, and my BOV is set really soft.

What I think it is... is where I hacked the upper IC pipe to install the 3.5" LS-1 Corvette MAF sensor. I didn't change the pipes much at all to route them to where they originally went, but I think the reducing couplers where it's installed are swelling at 21 PSI and using the lower-half of the upper IC (where the BOV is installed) like a crowbar. I think this is forcing the intercooler's outlet pipe to the side and breaking the welds. It couldn't be doing this from engine movement because I have it all locked down with polyurethane, so I think it's a leverage thing. I think I need to do something to brace the upper IC against the body so that the pipe can't move at all or put any pressure on the IC outlet pipe.

The intercooler is locked down tight. I spent a long time trimming parts and adding structural support so it can't move at all, and nothing rubs on it.




I'm gonna stop pic-whoring for the day now. Does my theory make sense? I have a dyno video with a shot of my engine, and that pipe looks like it moves quite a bit, but the motor doesn't really move. I fixed the intercooler the day before dynoing it. It broke a few days later.