Here are some pics of my intercooler setup. I don't have a tube bender so this is what I came up with using exhaust tubing.
'99 psd intercooler, 2 1/2" exhaust tubing (painted on both sides), silicone boots from siliconeintakes, PSD intake hat thanks to Ottoparts via Typ4.
Setup - all mentioned above +, 6.9l, ZF-5, 3.55 gears, 33 inch tires, IP turned up 1.5 flats, (not sure on injectors), non-gated banks turbo, K&N filter (not the best), 4" straight pipe exhaust, RDT, and dual e-fans. .
Results (empty) - 4th@65h = 2300rpm on flat = 1 1/2 psi = 300 degrees
Results (loaded towing 9000lbs) - 4th@65mph on flat = 2300ish rpm = 4 psi = 450 degrees
4th maintaining 65mph on 4% grade =2300ish rpm = 8 psi = 700 degrees