Intercooler is getting the best of me. I got an " good " used one shipped to me so i took the car apart while waiting for it to arrive. My old intercooler had a light coat of thick fresh coolant in the exit and Y so it was leaking. When i recived the new used intercooler i tested it at 10lbs in a tub of water and it leaked bad so its junk. I decided to test my old intercooler the same way and i could not find a leak so i filled up the water ports with an rad flush and plugged them with pipe plugs and let soak for 6hr. Removed the plugs and blow out the rad flush and allot of thick clearish fluid with chunks of gel came out so it did this again and this time no gel chunks with some thick fluid. I rechecked it for leaks and still could not find one so i turned up the prusher 10 psi at a time and stopped at 40psi as i was get scared i might blow it apart. At 40spi i saw a very very small leak one pin head size bubble every 90 sec so i am very confused. Thinking this leak must open up and get worse with heat but to check that would take allot more. I decided to stand the intercooler up with the exit down with 20psi for 4hr to see if any fluid would leak. Teap it leaked a little thick nasty brown fluid from driver side of the core so now i know where the leak is coming from. So i am thinking i could cut off that tank inspect & clean it well and reweld it back on but has anyone had any luck repairing one ?