nice motor Jamie, she looks well looked after.
check this thread regarding intercoolers:
http://vwdiesel.net/phpBB/viewtopic.php?t=5716&highlight=intercoolerhopefully it will give you a few pointers.
i am also adding pics of my intercooler added to my mk3 aaz engine.
inlet manifold turned around facing the other way and egr valve blank:

intercooler pipes in engine bay 2" all round:


pic of my motor running bumper ducts:

aluminium tubing (from diy store) to air filter:



hope that gives you some ideas.
i also have added the intercooler from a mk3 tdi and used its original bracket to mount it - bracket and bolts from VW, intercooler from scrappy/ebay.
A Sharan/Galaxy one (see photo)

will fit into the front bumper if you remove the slats!
I have one but dont have the time to fit it - currently renovating the house - have been since September 2007...
My boost is turned upto 1.0 Bar by Derv Doctor in Derby which I believe is the Governer Mod. Search the forum and you will find lots of info.