Why not go aftermarket? No more plastic end caps to worry about. Lots of debate over which are best - Tube & Fin design transfers heat more effectively, Bar & Plate much sturdier in construction..... There are hundreds of different designs surely one would suit take your pick
The KJ intercooler is part of a stack assembly with the AC condensor in front, the radiator and intercooler, all held in place by plastic tabs etc so where would you mount one of the after market ones? If after all these years no one has managed to do it I would put it in the too hard basket.
Do all 3 then instead of forking out $2k for a single OEM intercooler otherwise I hope you're good with the play dough because that seems like your only other option by the sound of the thread
I have repaired my intercooler end tank and also ordered a new one from the US. just in case so now the repaired one will probably outlast me. Price from the US wasnt that bad.
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