First, you have
to obtain an intercooler! I was lucky enough to have another 2G
Turbo Probe project person, Dan Dunhem, stumble
upon a stock front mount intercooler out of a 1987 Starion. This
picture of it is after an hour and change spent cleaning it up.
First round was a fine wire brush to knock off all of the years
of road grime. Round two was an hour spent buffing it to a mirror
finish using Mother's Aluminum and Stainless Polish. So that's
it...a little elbow grease and it looks beautiful.
After cleaning it up, it was time to tear apart
the front end and make it fit, if at all possible. After
removing all of the necessary nuts and bolts and pulling the
entire front clip off, I test fitted it 
without making any
modifications to either the IC or the car. I tacked the front
clip back on to see where the IC would hang. Naturally, it was
way too low. The support beam for the hood latch system bends
forward and cuts the free room down substantially and thus would
not let the IC up any further. I tried several times to get the
IC higher, but the hood latch brace had to be removed. The photo
to the left shows the hood latch assembly (tell-tale yellow
button) from underneath the car. Originally, a large vertical
bracket ran from it and then attached to the car under the A/C
condenser. The loom is wiring to the fog lamps and the metal line
is apart of the A/C system. This line has plenty of
"play" in it to be pushed back for enough clearance.
With the bracket out of the
way, there was more than enough room for the IC to be brought
directly up to the bottom of the hood latch. The short inlet on
the IC (see photo) had to be trimmed slightly as the tube pointed
forward and came to rest directly on the bumper. This is not a
big problem as it faces the wrong way to begin with. A little
trimming and the proper connector, and it now points to the
driver's side of the car where it will meet the plumbing from the
turbo. The outlet already has the pipe attached to meet the
plumbing to the VAF....very handy.
I temporarily hung the IC in place using tie straps and again refitted the front clip to see what was what. It was perfect...well, almost. An inch or two higher would've been OK, but the IC was clear of any obstacles and high enough not to substantially protrude from under the car. If I had cut the long pipe off and routed straight pipe in it's place that wasn't angled so high, it would tuck perfectly under the front lip. This is still an option as the front will need to be removed at the time of the turbo install to make the plumbing connection. This is only because I installed this out of step and knew it full well when doing it.
After removing the front clip again, I marked its location and began making brackets to permanently mount it. I used plumbers strip (aka pipe strip) to run around the top IC pipe and bolted that directly to the hood latch assembly.
It is a little difficult to see in the
photo to the left, but the strap runs tightly around the pipe and
is then bolted to the hood latch.
It as at this point that I realized the hood latch brace needs
to be put back in place. It was fine on its own, but with the
weight of the IC added, it became flimsy. Obviously the stock
brace would not fit. I fashioned another brace out of strong
metal slats (tie-beam connectors from the home improvement store
of your choice). The important thing to note about them is they
are straight and strong. Using two of these screwed together, I
bent the metal to accommodate the IC and then again to meet the
hole where the original brace was attached. The top part of the
brace bolts behind the strapping retaining the upper IC pipe. Now
I have a nice solid support for the hood latch and the IC. 
Down on the sides of the IC, there are two mounting brackets. Again using the plumber's strip (doubled-over for strength), I attached these brackets to existing bolts in the A/C condenser frame. These bolts are located at each bottom corner of the condenser and make the perfect mounting point.
After it was all securely fastened to the car, this is what it looked like before re-installing the front clip. Looks nice, huh? Notice how the top IC pipe is visible through the hole in the bumper. The inlet is directly below it. Both pipes will be run through existing holes that will be enlarged and will then enter the engine bay between the radiator and driver's side headlight.
These are the finished photos. As you can see, the IC hangs about 1.5" under the valance. For the price and the application, I am more than happy with this outcome. If at the time of the turbo install I decide to cut the upper pipe, the unit will sit completely above the bottom of the valance. Also note here that I did remove the plastic vertical braces that were just to the inside of each fog lamp. These came to rest slightly on the IC end tanks and while it would be feasible to keep them, I opted not to. As soon as I get new film, I will take some head-on shots during the day. This thing looks sweet sitting in there with the sun gleaming off of it....even if there's not turbo in it yet!