The bigger the core the more air that can flow through it easier. The smaller the core, the harder it'll be for air to get through (thus more lost psi in a smaller core). It is better to go with more height and width than going thicker, but you can only go so wide and so high (due to space restrictions in your front bumper) to where you need to start adding thickness to it to allow more air to flow. Precision is right in what they're saying because you want it to have a bigger face to catch more air on it as thickness won't be as effective. That's why I was saying that you can't just say you need X" thick intercooler to support "X" amount of hp because it also matters how tall and wide the face of the core is.
You're starting to overcomplicateing things at this point as you just need to pick one out that's proven to support the power you're looking to make. If you go to VS racing and get the 4" intercooler (if you can fit it in your bumper) and you will hardly see any pressure drop and it'll give you room to grow power-wise down the road.
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