Mounted the intercooler!
Well measuring and removing AC, Aux fan, air horns, etc payed off! The 16x13x3" intercooler I purchased fits like a charm. I realize I could probably have gone about 2" bigger across but I didn't want to risk messing with the high beams and the PS cooler bar. I also like the fact that with the bumper back on and all, the end tanks stick out of the kidney grill but are mostly shadowed. Keeps the "hey look im turbo'd" aspect pretty low. For the air in and out, I will be using two 2.5" silicone 90 degree bends and dremeling holes thru that lower plastic piece in front of the rad. Works freaking perfect!
Oh yeah - I used 3/16" flat steel bar. What a bitch to bend! It's a "little" overkill for a 12lb intercooler, but the thing does not BUDGE. I wanted to make sure that I never experience an issue of something rubbing. I had a supercharger silicone hose rub thru a brakeline... never again. The cooler is actually in there more securely than the radiator.
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