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If you can’t get them warranted, you may be able to get them welded. Do you know if it has been leaking there the entire time you’ve had it? From the location it looks like the welding pulled the separator sheet back and opened a leak. It could have weakened it and then the leak developed later. Welding on cores is extremely touchy, the welder really has to know what they are doing, because it is really easy to burn through the separator sheet. If welding doesn’t work, or you can’t find anyone willing to do it, you need to knock out the fins till you can directly see the leak, and use a strong, heat resistant epoxy to seal the crack. Orient the intercooler so that the epoxy will pool at the leak to cure. Something like JB weld could work, but I think you will want something that is a little thinner. JB weld might flow better if you heat it up, you might want to try on a test piece first. Of course make sure that you clean and prep the location well. Good luck,
Dan
-Dan "Capitalization is the difference between helping your Uncle Jack off a horse, and helping your uncle jack off a horse."
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