Holy crap, you're still running the stock intercooler at that boost level?!? You are asking for a blown motor. At least get some kind of SMIC that works with the stock piping. Pretty much anything you choose is going to have less pressure loss and be more efficient than the stock intercooler; and it'll still "appear" stock.
Good luck man, hope you know what you're doing...right about now your rods are screaming for mercy.
chemical intercooling is more efficient then air to air. The intercooler is actually an interwarmer compared to what methenol injection does.
upgraded IC = beh. Trust me Ive had a fmic, see sig. injection does a much better job.
Just to let you guys know since it seems most dont realize whats going on here:
when you inject the following things happen:
1. the intake temps are lowered as the air is chemically intercooled, depending on what mix of water/meth you are running it will cool the charge accordingly.
2. Combustion temps are lowered
3. Exhaust gas temps are lowered
4. Highly potent fuel is added to the charge. The detonation resistance it adds is spoken to be higher then 116 race gas depending on your mix.
5. Cylinder heads temps are lowered overall.
There are a few other points, but that sums it up for the most part.
Methenol fuel dragsters run 30+ psi with no intercooler whatsoever. The T25R will never be able to heat up the air more then the injection system can handle.
If you guys remember from my old posts, on the old motor I was running 14psi for quite some time, no problems. With very poor tuning and only a single needle mounted just before the throttle body.
The new system is tuned quite well even with my makeshift controller and can supply more fuel/cooling then any streetable turbo can throw at it.