When I added a supercharger to my Durango, I needed an intercooler. The key to keeping air temps down in a street-driven vehicle is a big reservoir, not big fans and an exchanger. So here is my build from mostly stock parts, and a little help from my friends at Wal-mart.
I didn't want a big intercooler in front of the radiator, so I chose to use 2 Durango heater cores as the intercooler. They tucked up real nice behind the lower radiator support, and should be pretty well protected for off-road. I attached fans to each, which will run continuously. This keeps the IAT of my 600 or so HP engine about 20 above ambient, even on a 100 degree day.
Gates Powergrip clamps make nice hose ends.
Pump is placed on a 1/2 piece of pipe welded to the frame on the passenger side. Hose exits through the front of the fender, into the fenderwell, then into the pump intake.
And now for the creative part of the intercooler setup. I started looking for a good reservoir for the system, and found 1/2 to 1 gallon aluminum running $80 to well over $200. So I called up my friends at Walmart, and they happened to have a 72 oz Bubba Keg for $15. Tap the bottom, tap the lid, put in a couple of fittings from Lowe's,and there you are.
Final picture before the radiator goes in.