Easiest solution for your intercooler design is a FFIM. Mo' money!
When I first got mine, I looked at it carefully to check for crappy welds, holes, cracks or other problems (i was skeptical of its ebayness). It seems that it is just a regular intercooler with one of the side outlets cut off and welded shut (very cleanly) and a 90 degree elbow was welded to the bottom of the side tank facing the other way instead. I thought it was a pretty cool idea actually.
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