This is how things look now:

I've had a good look (and feel) round all the pipes, checking for anything that could be loose. I can't find anything, all the pipes and bits seem to be ok, but I will look again tomorrow to be sure.
Now that I have the intercooler off, is there anything else I can do? I've come this far so I'm willing to go further if it means finding the problem.
I also checked the air filter, looks nice and clean.
I have noticed a small oil leak, this is nothing that needs attention yet.