I blew my bar and plate intercooler a few weeks ago running 90-100psi. I emailed on3 a few times regarding their intercooler. They sounded OK, typical bar and plate, they said that they could handle 100psi but, they don't come with an actual warranty.
I was still giving it some thought, but then cut open my original intercooler and found that there was mayhem. Besides the obvious ballooning on the outside, and number of tubes had the stuffing blown back a couple of inches on the inside. After seeing that, I decided that I'd steer away for the bar and plate design. Ended up going with a BD, their design is different from most of the others. It looked a lot stronger, and that it would flow great, but that it might not cool as well due to staight through flow (but that's just my guess).
I ordered the BD from XDP, but after a week of waiting I found out that they were BO. Canceled that, and bought one off of Amazon for just over a grand with free shipping, got it in 2 days. It's a beast, weighs 20lbs more than my old intercooler, can't see 100psi of boost straining it it at all. Fit like a glove, required no sheetmetal adjusting at all.
Definite power increase over my old intercooler, but I can't say how much yet, cause I blew my head gasket just after I put it in. I'm guessing that's from the log jam in the old intercooler raising the drive pressures. If it's 90psi+ on the manifold side, and the intercooler is restricted, where did that put my drive pressures???