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Been following along on your build. I to am doing an front mount intercooler on my G60. It's a rather large intercooler I don't have pics of it at the moment. I also plan to use a dietrich type front bumper mine is actually the Rieger made out of ABS and plan on cutting out the plate recess for max air flow. My intercooler will require to trim the rebar don't know exactly how much I can say the intercooler I'm using is a spearco with in out on the drivers side. Sounds like you will be using a rallye type intercooler. I plan on keeping my A/C.
Can have pics if anyone is interested.
Thanks Pete
BTW here is a couple of pics of my G60 with doggers new wing.

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