If the intercooler pipes are bead rolled (as they all should be) there is no way a coupler should ever come off with proper T-bolt clamps. I have built intercooler pipe kits this way for a long time, and have a couple of local supra guys that are in the mid 30 psi range, and they have never had issues with the couplers poping off.
Check your vacuum lines (BOV, wastegate and EBC) there can end up on exhaust pipe if not properly tied up, and cause the issues you are having.
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