Take a look at the intercooler's fitted to Transit Connect's (these ones : http://www.belrent.be/transit_connect03.jpg )

I'll try to remember to get a pic in daylight 2morrow for you, but they have a decent sized single pass cooler fitted to them, and IIRC it's all metal And knowing Ford it can't be too expensive, even brand new! Specially since quite a few people on here work at Ford's