Off road rally track is always quite unpredictable, stones, bumps, jumps, branches etc. can damage radiator easily and it happens regularly. We wanted to avoid a front mounted intercooler firstly because of its safety during rally and secondly because it would be creating a drag for the radiator. Top mount intercooler with a proper scoop is safer and would not hinder the fresh air for the radiator.
At this moment I do not know if and how many bends the intercooler has but would keep your suggestion in mind and remove as many as possible, at least 90 degree bends can be taken care of.
Evo is to be used for off road rallies and since there is hardly any traction on loose gravel, dirt or sand, especially at triple digit speeds, insanely adding bhps is of no use because it will only add the useless wheel spin, resulting in even poorer handling.
I have been told that a Stock JDM 2JZ GTE, running on stock 1.1 bar, produces between 300 and 320 bhps. This is reasonably higher than my Evo's 6G74 Mivec motor, which used to produce 280 bhps in 1997. For the testing and initial one or two rallies, this is more than enough. If required, we will change to stock 2JZ turbos with steel turbines, which will also add around 15 bhps. Addition of performance intake, exhaust headers etc will add another 10 to 15 bhps.
I do not think i will be needing more than 350 bhps for off road rallies in Pakistan, so there will be no need to play with the internals of 2JZ.