Tony, I just reread this for about the 10th time, trying to glean all the info I could about the engine and intercooler. Every time I read it, I find something I missed. This is a really great thread!
I'm getting ready to start on the intercooler, and will soon start on the engine.
They say "Imitation is the sincerest form of flattery"- If that's true, I must be your biggest fan, because I plan on 'copying' a lot of what you are doingon the engine setup.! Thanks for all the detail.