Thanks for all the valuable information regarding the intercooler and plumbing. Here's where I'm at right now. I have decided to drill and tap the top of the "downstream" side of the intercooler for a small vent line, which will dump back into the icewater tank. I think that will give a good path for any air to escape the intercooler core.
I'm planning on keeping it horizontal for the sake of simplicity and packaging.
The notion to weld an Al 90 degree fitting onto the turbo is a good one. I haven't totally committed to this idea, but would like to. There are some other critical items that MUST be done, and this item is slightly below those on the priority list.
Diesel Fuel Injection Services has my injectors cleaned, tested, rebuilt, and balanced. I'll be picking them up this evening.
I have a call in to my transmission guy. As soon as he's done with the 4-speed rebuilds, the real engine will be going into the truck "for good".
Yesterday, I received a better-flowing, and better fitting intake manifold from a guy in Bulgaria. This is one of those "Never available in the USA" parts.
The gauges have all arrived - Big thanks to Tman for sourcing the gauges.
There is plenty of fabrication, wiring, and plumbing still to be completed, but I'm hitting a pretty good groove of catching my second wind after my day job, burning a little midnight oil.
Steve.