Unfortunately, the group buy for the TyrolSport intercooler didn't work out for me.
But... The company that supplied my new turbo was willing to send me an intercooler with the turbo to try. JM Turbo Coopers, not only has excellent customer service, but their intercooler fit with almost no trimming or modification. (Tech at mini dealer who did the instal stated only needed slight trimming on a left side body panel.) The dealer also said that construction and setup was better than any intercooler they had seen yet.
After driving for a few days, I am really impressed. Given I replaced Turbo with a JCW ported and ball bearing turbo, new plugs, intercooler, clutch and filter element, so judging intercooler alone is near impossible. All the parts together have made this car a monster.

 

What exactly is a ball bearing turbo? I know what a turbo is and I know what ball bearings are, but I have never heard of an upgrade where the turbo got some sort of bearing upgrade.

 

The newer Garrett turbos use ball bearings instead of journal bearings. I haven't heard of upgrading a journal turbo to ball, but then I'm a novice in regards to turbo tech.

http://www.turbobygarrett.com/turbob..._ball_bearings

 

Sorry, I kinda worded that weird. Basically the stock Borg Warner K03 turbo comes standard on all Minis except for the JCW models. This turbo is only safely rated by the manufacturer at 190hp. I had it over boosted with a custom tune, but it was not my ideal set up. JM Turbos offers a K03 S or (K03-2074) that comes standard on the JCW's. It is rated to a safe 255hp.
As far as the modifications, the stock turbo DOES have bearings, but they are not the quality of the 360deg thrust bearing. This allows my turbo to spool about 500rpm faster than stock. The compressor housing is also changed from the stock 37mm to a 40mm housing. This gives the car more a smother more constant power band with drop off occurring around 6200RPM instead of the stock 5400RPM.
I'm currently running my set up at 18psi, which I plan to keep since it is a daily driver. Should have a dyno run within the next few days to post.

 

Excellent, where are you getting the AWD dynoed at locally? Been wanting to just get stock numbers on my R55. Also, how is the dealer for all of the mods? I wan tot get an AP but am worried about losing my 6 yr 100k CPO.

 

There is an all wheel drive dyno now in Bonita Springs. It's just past Bonita Beach rd, I believe just next to the Delorian dealer. Be cool to maybe set up a Mini dyno day.
I have the AP for my STI and it is really a great piece of equipment. My only concern with the Mini is lack of upgrades and support. It does have a function to uninstall and will not leave a foot print, so the dealer will no know it was installed. (Unless you change rev limit or exceed governer.)