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What have you done, stuck a bit of Magic Metal over the join? How long is that likely to last.
 

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Couldn't get the pictures to load but I thought the intercooler problems were with the plastic (or whatever) end caps/piping on the intercoolers splitting which only affects cars from 2011 on (i.e. DBA). The CBA's are all metal, don't have the plastic.
 

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They all corrode and split over time as there’s no difference in construction. The core and end tank are joined by a small, thin metal strip that’s crimped on. On the second picture I’ve used bar and plate core instead of tube and fin, and welded the tanks on.
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Thanks Skint, that is helpful. I haven't experienced it and so didn't know what to expect. I had been thinking it was where the clamps for the piping go, not the core so good to see what's what. The welding looks MUCH stronger than the original crimping (y)
 
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