Headers are probably not worth the cost IMO. Better to leave 'em alone, or port/polish/coat them.
And I should think you'd be fine w/ a 20G on a stock STi intercooler if you're running a smaller hot-side like a TD05. You're not going to be making the big top-end flow that needs the big intercooler. I know MikeK's got a stock STi intercooler... which he switched back to from a big APS FMIC when he went from the GT52 to the smaller TD05-20g.
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