I will be looking into designing my own custom Front mount intercooler soon, but I need to decide on a core type to purchase....whats the best to go for? there seem to be so many different varieties out there all claiming to be "the best" Bar and plate, tube and fin, some with internal fins, some without, some with aerodynamic looking shapes so on and so on. The choice seems limitless.

whats everyones recommendation?

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ST205

There was an extremely long thread on OC about this exact subject it started off about end tank design and went from there. Makes for good reading. I have also found this on my travels:

http://www.are.com.au/feat/techtalk/tanks.htm

I think that most of this seems fairly sensible.