when to upgrade intercoolers?
You will be fine with your stock intercooler unless it cracks or you get in an accident. We have had trucks push well over 60lbs through a stocker. When they really start to be a benefit is when you are runing a setup like the 2.6 truck we have in the shop. Where the air is 650* coming out of the turbo and then gets down to 110* at the intake. But that is on a truck where every inch matters.
we ran 100 psi on a stock intercooler and it was fine... then blew a hole in it and got another stock one... if you need to drop egts do an air to water prior to the stock one... plumb it up with a radiator to circulate the fluid

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