Yep, I like that intercooler idea. I would seem to fit nicely if the radiator could be dropped down. It will be good to keep the pipework as straight and untangled as possible. I did think about coming out the front and low down, but the bumper recesses back a lot at that location. I also toyed with painting the intercooler the same colour as the bumper (Black) and running outside of the bumper in front of the car. Making use of one of the more square, squat intercoolers, but in my imagination it might look a bit crap.
I think the best thing is to get everything dry assembled and then offer bits up - radiators / intercoolers / large radius bends etc and see where it all fits best. I can see what you mean about suggesting bringing pipes out and below the headlights. That does seem like quite a good idea and then would give you very direct horizontal unimpeded access to the intercooler.
I think it is going to take some mocking up and fiddling.
I also need to sort out other stuff, like over pressure waste gate, 5th injector, MAF location, throttle body etc. Getting close to buying the supercharger now - just trying to work out which will be best. It seems most likely to be the Merc one from something like an SLK200. (Easton 45).