Bet the intercooler is lifting slightly under boost allowing the ring seal to dislodge ... then poof.. it goes.
M2C
Johan

that's a cut, you did it putting the IC on.
put grease on it

No, it's not a cut, and yes it was lubricated when I assembled it on my work bench... I was very careful in the assembly, as this was the second one I had fail, and I wanted to eliminate the installation as reason for failure... Philip

I had a similar setup, with a silicone coupler on the turbo side, and o-ring on the intercooler side. I had nothing but problems with it. O-rings would pop out or break, and sometimes the whole pipe would pop out. The oil film in the tube, combined with the boost pressure would always eventually allow it to slip down slightly at the turbo side, no matter what I did with clamps. It was one of the many factors that led me to switch to the turbokraft intercooler with v-band connections. Zero problems ever since.

The only time I had one like that was when I had not seated it properly. It was pinched when I put the IC over the TB. As suggested, maybe a a bit of silicon lube?
Hopefully Rawknees not looking.
Alan

I think DOS531 is onto something. My car spit out that o-ring during a track day. I thought I blew the turbo with the oil and loss of boost.
I thing the heat and oil blow by was just too much for an o-ring that close to the turbo.


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the IC needs to be bolted down. it should not be moving and it will blow off.

I have the RUF setup.
a silicone coupling from turbo to the up pipe. the IC has 2 orings, one for the up pipe and one for the TB. my Oring looked like yours when I tore it. I am certain I did it putting it on. only did it once and never again as I am more careful putting the IC on.
the IC is also bolted down well.
it has a bracket from the ic to the up pipe that keeps them together. the IC is bolted to the fan housing next to the up pipe and it is bolted down on the right side next to the TB.