I had a chance to build up a simple shroud for my intercooler. Here is a pic of it.
Here is how it looked in the pattern stage. It is 0.25" aluminum. I actually like the 0.025 aluminum sheet found in the aviation section at Lowes for pieces like this. I find it is easier to bend that 2024-T3. The next picture shows it on my DIY wooden sheet metal brake I made out of old hard wood maple doors and a hardware hinge. Works real good. I do find it helps to duct tape the piece in place. Keeps it from creeping while in the clamps. With metal this thin you can simply hold the metal or wooden brake by hand while it is being bent.
Here it is attached to the intercooler.
The only down side to this set up is it did not allow for a nice outlet that is plumbed to a negative pressure area. While this would be ideal, I am going to wait and see how well it works as is. I have seen very nice temp drops with the intercooler on the test stand with no shroud at all, so I think my IAT (inlet air temps) will be reduced at least as well as what I saw on the test stand (60*F-80*F) and probably much better, and if that happens this will be more than enough to get me where I want my IAT to be. Given that very small amount of boost I plan to use <7lbs This should do just find.