I've seen a few Squires Turbo setups, and they are well made, and work fine.
I've thought about doing this very same thing to my last 3 Audi's, as I've owned a Turbo Supra since 1995, and would like the same type of "boost" on my daily driver sedan. (Nearly bought an RS6 for this reason.)
I'd be interested to find out how well the 4.2 with the higher static CR works out on a force fed diet. (I built a 9:1 static CR 3.24L stroked 7MGTE that was awesome on the street, as it had great power off idle, while still handling 18psi on pump fuel, but I coated everything that could be coated, and had forged internals to handle the stress.)
Even just a 5psi setup that replaces the rear muffler, would be worth the extra tourqe in the mid range, and of course, it should fill in the power too on top at high rpm.
My thought on intercooling is to use extruded aluminum formed with heat sinks on one side, similar to what they use on snowmachines. (They are 1"x4" wide, with 1/2" fins on "top" of the boxed section. Use two of these side by side to bring the boost back up under the floor, and merge them into a single 3" inlet to then blow through the stock hot wire sensor prior to the throttle body.) Should be light, and effective, but you'd have to merge the two at the turbo as well. (No big deal if you can weld aluminum to merge the boxed sections into one, and then into a single 2.5" inlet side that you can hook up to the turbo compressor housing outlet.)
The oil less Comp Turbo would be awesome too, as running cooling lines back to the turbo would be easy compared to oil and a scavange pump return system. (Heck, you might be able to just mount a seperate rear pump for coolent, an expansion tank and stacked plate cooler tucked up at the rear bumper in air flow there would be enough to cool the CHRA, especially as it's on it's own, so no engine heat added to the coolent, and the turbo would be back away from the engine, so quite a bit of heat is lost in the exhaust system distance anyway too.)
Just thinking outloud, give us an update if you have any news.
Thanks.
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