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If you are worried about space in front, maybe a side mount? A fair few Polo GTI guys have them sitting around (I do...) so it would be cheap and drop your intake temps by a few deg. They hold up to the 20ish PSI a chipped 1.8T kicks out, but they will heatsoak in summer with that much boost.
you can fit a 2.5" thick core in front of the radiator without cutting anything really, just elongate the holes in the radiator bottom mounts a tiny bit for an extra 5mm. a 600mm wide core will fit right across the front like the pic posted just earlier, and with a stock engine bay you can have the piping come out from under the battery tray on the passenger side. the intercooler cant be more than about 240mm tall because of the bonnet catch, unless you don't have a bonnet catch and are using pins instead.
we did this on the mk1 TDI we built.... worked fantastically well. also only took about half a day to mount the intercooler and plumb it all in, but then I am pretty awesome
'07 Touareg V6 TDI with air suspension
'98 Mk3 Cabriolet 2.0 8V
'99 A4 Quattro 1.8T
plenty of room for a front mount just have to run pipes down either side of the engine, lag shouldn't be a problem depend on the size of the turbo which im guessing isn't huge anyways , how much boost you running? and dyno figures??
Thats the one that was for sale a couple of times yeah?
Do you have pics of the whole set up. I remember it only being a turbo manifold, turbo and fuel pressure reg. Its cant be that simple can it? If it is, i want to give it a go!
How do the box and internals handle the boost? Is there much slip.
I have custom made 4 into 1 steampipe manifold, vr4 highflowed turbo, 2.5 inch exhaust, blow through webber carby, repco thumper primer fuel pump feeds a vl turbo fuel fump which goes through a malpassi 1.7 to 1 fuel reg, freshly rebuilt engine, 1.6l, mahle pistons and rings on standard rods with arp bolts,210mm bras button clutch not to mention last week i spent $1000 on getting the head ported polished decompressed and a new headgasket. Thats what has been done to mine but im sure you can get out of i cheaper if you wanted too ... my headgasket itself was $400 but they had another one i could use that was $140 same thickness.... im sure you could do it all for half what mine cost !!
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