Thanks again Dieselman,
I see the logic in your thinking and am sure it would work, I did a similiar thing with an old MKII Escort, polished all the inlet ports and matched the inlet manifold to the block by removing the 'humps' where the two join.
I like things to look OE and even though people dont see under the bonnet I wouldnt want it to look all bandaged up. I thought an intercooler upgrade would be a simple bolt on job. I must admit mine does look like it has seen better days, there are numerous bent fins due to stones and flies hitting it. I have had a look from underneath whilst on the ramp and there is physically no room to fit a bigger one in.
Just have to be content with what I have, which basically I am but I heard that an intercooler upgrade can gain another 40bhp in the likes of Discovery TDi's and similiar.