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Here are the pics of my intercooler. It was constructed from a pair of JZA80 Supra intercoolers joined together in parallel with custom end tanks. As you can see, this makes for a very large intercooler - it measures approximately 6 inches thick! There's a fair amount of weight in this thing considering it's made entirely out of aluminium, so it should be very effective as a heatsink. The squared-off design of the end tanks isn't exactly ideal, but considering how thick these cores are I think it will flow quite well regardless.
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OK, it's time to bolt this thing in! I bought some aluminium strips, cut them to length and drilled a few holes as appropriate. This stuff is really easy to work with, even if you're a gumby like me.
Next, holes were drilled in the intercooler mounting tabs to match.
Then, the aluminium strips were bolted onto the front of the car like so. In this position the intercooler will be mounted further forward than it could be, but there is plenty of room left for the air conditioning heat exchanger. It would be nice to have the aircon working eventually!
And here's the finished product. The cooler is held in place very securely - there's no way this thing is going to fall off! Note that the outlet on the bottom tank is low enough to go under the left chassis rail. The outlet on the top right will be a bit more difficult though, as there is not much space between the end tank and the headlight assembly. It looks like the electric motor can be moved lower to give us a bit more room, so we'll do that if necessary.
Finally, we did a test-fit of the front bar to make sure there are no major clearance issues. The centre support strut had to be cut off, but apart from that everything fits just fine! The cooler will be completely invisible behind the spoiler, which is great for the stealth factor. I will probably manufacture some supporting brackets out of aluminium to replace the strut that was cut away, but that's a job for later!