Finished the intercooler mounts last night and painted them up. But wasn't really worth a thread update so here it all is.
Intercooler is mounted, nice and solid on some 3/16" flat bar with tabs welded on. I cut a slot for the turbo cold side to go to the intercooler behind the lights on the passenger side. Just need the elbow to come in tomorrow and that side will be done. Might have to trim the inner to put it back in but I think it'll fit.
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Mocked up the intercooler outlet side piping, decided that I really don't like my junkyard mustang fan so that's good to need upgrading. It's way too bulky and is a real pain to get air piping around, the UMI brace isn't helping either.
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Still needs trimming and final fitting but its 90% there. Everything clears with the header panel back on. Mock up complete. Tomorrow it gets finalized.
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Got the tune tweaked and ready for upload today at work. Just need to flash, check sensors and fire it up. Still some small other stuff to do but it's mostly reassembly now.
Oh? You no done yet? That's a too bad for you, slow poke.
Kidding.
What diameter pipe is your downpipe/exhaust? Might have an idea.
As for the piping. You are either going to want to go under the core support (like GNs do) or through it (via the headlamp holes) like you've done on the PS. Your proposed DS solution is very convoluted right now. Alternatively you could just hole saw the plastic fender liners - if you aren't worried about stock appearing or the condition of the parts.