This is interesting Mike. I have my B&M 70264 cooler mounted to the AC condenser with the zip ties and it's probably been on my rig for around 40,000 miles. But, I haven't done a ton of hard off-roading with it either. Between the cooler and the AC condenser, I used the supplied cushions so I don't see how that could cause a hole to be worn into the condenser. Now on the back side, if you chose to run it through just the condenser and not the radiator as well, I could see how the hard plastic ends locking the zip ties in could possibly end up wearing a hole in the AC condenser cooling channels with some movement in the cooler.
On my 2000, I ran the zip ties through both the condenser and radiator. On my 1998, I ran it just through the condenser thinking this would be the smarter move for future work like doing a timing belt job and you need to pull the radiator out causing you to cut the zip ties that hold the cooler in place.
Can you let us know exactly where the failure happened with your AC condenser? Was your cooler a little loose allowing it to move on the condenser or was it locked down tight?
I chose the zip tie route because I figured this was the best option for allowing the engine fan to pull air through it. Using the brackets, you can probably get it pretty close to the AC condenser but there will still be an air gap between the two components. So, at a stop or slow driving conditions, the engine fan might not be pulling air through the cooler but rather around the cooler. Maybe the difference is minimal, but I figured you would get more efficient cooling with the cooler mounted directly to the AC condenser.