My thoughts would be to do it as if you were doing a hidden winch, which will sit it out the front around 3-4", cut out the centre section of the bumper, then just make a light alloy skin to mate back to the bumper. That way you keep your angles. I know some of the other CRD guys were looking at different intercoolers which would mean more room but I dont know how it went.
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^^ I like that idea.
Hell might even be a good chance to play with fiberglass if you wanted to get fancy
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