Here is a photo of the old setup
The setup consists of this style of intercooler:
On the outlet of the cold side of the turbo there is a 2.25 inch OD 90 degree elbow that gets welded to the outlet of the turbo to turn the exiting compressed air so it faces forward to enter the intercooler. The elbow looks like:
After passing through the intercooler, the now cooled air enters a 3 inch OD thin wall aluminum tube that routes the air into a large 65mm throttle body. This tube before it is modified to fit the application looks like:
In the side of this 3 inch diameter thin wall tube leading to the throttle body is a 1.5 inch outlet for an aluminum bypass or diverter valve like this:
The outlet of this turbo bypass valve connects to a similar 1.5 inch connector on the tube leading to the compressor side inlet.
The system needs a pump to push the water around in the system. This Bosch intercooler pump is readily available on Ebay and pumps around 5.3 liters per minute.
The approximate cost for these pieces is:
Intercooler: $124
90 deg cast alum elbow: $20
Bypass valve: $20
3 inch OD thin wall alum tube w/90deg bend: $25
Bosch 0-392-022-002 pump: $100 - $110
