[8valver]

To be honest Brian, It depends on what you are after long term. You can bolt in a cheap and cheerful intercooler like getting a corrado G60 one and making it fit or something else of similar size but if you think you are going to get bored on the power down the line and want more then you will need to go for a larger FMIC and will end up spending the money twice. A sprinter one can be picked up for reasonable money and probably even cheaper on ebay, You will need custom pipework though. Alternatively you can look for a Golf/Rallye G60 one but again you will pay Anywhere between €200-€300 for a good one of these and again you will need the pipework to go with it.
Dont scrimp on this as it could be worth BHP to you in the long run. If it were my car and I have been in this postion in the past do the job once and do it right. Nobody ever said these conversions are cheap to do and we all want our cars on the road ASAP but sometime it can be the best move to hold off until you can afford the right bits for it. If the absolute last thing you are waiting on to get the car on the road is an intercooler and pipework then you are more than on the home straight.

 

[8valver]

Brian, the pipework for a sprinter intercooler and fitting is reasonably straight forward. You will need to make up a few brackets to fit it but its fairly easy stuff and a small bracket for one side of your rad as it will be pushed out a bit. The only awkward piece is the charger to intercooler side. With the Rallye U bend though this is obviously a lot easier. When you fit the cooler the inlet side (ie the charger to intercooler pipe) is on the drivers side of the car or left hand side as you look it at from the front. Its down low in the intercooler which makes it easier for you with the rallye U bend. The outlet from the cooler is on the passenger side or right hand side as you look in and this is basically a somewhat straight piece to the throttle body. If you had 2 samco or similar pieces for either end and a straight piece of stainless you would be sorted for that side. As I said dont stumble at the final hurdle, if you really wanted it badly you could have the it all sorted within about 2 weeks and thats allowing about 1 week 6 days for parts to arrive!!!

If you had all the bits there you could make brackets, fit and plumb up in a few hours.

Here, even found one for you!!!

Clicky ebay

 

[8valver]

The pipework would be fairly similar for a Rallye intercooler as the outlets are in similar places. If you got that intercooler on ebay for in or around what its at now it would be a cheap enough setup and probably a nice bit cheaper than a rallye one.

 

[8valver]

Well Brian, its the biggest cooler you will get in there and is more than up to the job. You can bolt it in and forget about it. If I remember correctly I think DaveC might have taken some pipework out of his car, dont know if he still has it but might be worth giving him a shout and see. Would save you a few quid I am sure and shout be a sweet fit.

 

[8valver]

No bother