I have a massive intercooler from a semi with an intake on one side and exhaust on the other. How difficult would it be to reshape this to install under the bumper? could I double layer it like one half in front of the other half and shape 2 new ends? It is designed for a 840 cubic inch diesel pushing 30 lbs. of max boost. I like the idea of ordering the kit intercooler but I heard the tubes need a lot of tweaking to fit, if I need to tweak why not start out 1300. ahead? I was thinking of routing the air tubes through the inner fenderwells and up over the engine for the intake. Seems possible. Opinions?

That's alot of intercooler.
In the Dmax they made enough space for one.
I would imagine you might have to do the same.
I've heard of a few ways. moving batteries, radiators and the like.
If you had a the knack to make a custom bumper you could incorporate the core inside.