Well I got on ok fitting the new intercooler, have no boost pipes connected yet as i need to order some corners and joints to fit it.
Like I said the other day, on reflection the 1.8T intercooler that takes the inlet down the back would be easier to connect using OEM hoses.
My setup is going to come from the turbo, down to the lower connection of the SMIC (as I didnt realise how low the turbo output was), then from the upper connector over the chassis leg and down to the crossover pipe to the other side of the car.
By trying to keep the in at the top - out at the bottom I would have to fit some extreme corners to connect up, and the flow would probably have been poor.
You can see in the pictures how I have fitted it, and have got a matching fog air ram/collector. The clips were different to the original N/S one so if you look to buy one, match them up from the same model of car! I have also removed the foglight assembly so there is a clear route for the air.
I have sealed the open intercooler ends with plastic and cable ties to keep out junk till I connect them properly. Relocation of the vacuum system valves is required on the 1.9 TDI. as they are mounted where the intercooler bracket is. I also had to remove the Helmholtz resevoir from the crossover pipe (black tank on small hose in drivers front corner, under the chassis leg), and block with a blanking piece and jubilee clip.