how should I mount my volvo intercooler?

just sit it in front of the radiator and make new brackets.
It will still get air, not as much as if it had the full surface area exposed, but it will get enough. you must take a choice between aerodynamics and cooling of the intercooler. NASCARS have as little as they can going into the grill.
 
351wcoupe said:
it seems really scary. Just imagine if you running 9000rpms and the car is running cool. You put tape over the grille to go a "little" faster and run your $55k engine a bit hotter. :p

The science of it is...

When you are running 160-190 MPH there is a sht load of air getting packed through that 4x2 inch opening.
Also, when you are running 160-190 MPH you want all the downforce you can get on the front wheels, that wall comes up really fast when you develop a push!