I did a one year placement in New Hampshire USA with a Biotech company. I was a computer Science student. I was basically an IT intern out there.
This was 2002 time frame.
How did I get the job:
My Uni had a wall where the placement department would post up all job offerings.
One day they posted up this job for the US. It turns out they had a placement student out there already and he was due to go back to uni. The student who was already out there got his job via his dad who worked for the company but in the UK.
I got chatting to the guy over email, asked questions, etc. I think this is what got me the job really, while a lot of people just applied for the job I took the time to speak to the guy out there and built up a rapport with him. Turns out he pretty much recommended me in the end which just shows that it's who you know
I had a phone interview with all the guys out there that was more of a chat than an interview.
I think applying blind to US companies would be very difficult. There could be a lot fo work in it for them around Visas, so they may be keen to get US students rather than UK ones.
Visa:
You would need a long term student/work visa, I believe this called a J1 or J2. My employer had to fill out a lot of the sections. I think this cost me a few hundred dollars.
Flights:
Pretty self explanatory. Expect to have to pay for your own flights. Also note that on a J1 type visa you can only leave and come back to the country once. For me that was Christmas and New Year.
Rent:
I took a room in a house. It was the old room of the guy I replaced so it suited me fine.
Rent was around $400 a month. Lot cheaper than what i'd pay in the UK.
Car
Depending on where you live you'll need a car. I lived in the sticks so I needed one. Bought a low milage Hyundai for around $3000. Sold it for $3600 a year later!
Even if you live close to work or have public transport still get a car. You'll want to explore the country or drive to friends houses.
Petrol was silly. Full tank was around $15 for me.
Job
I was an IT Intern. I was one of two guys looking after a manufacturing facility in New Hampshire.
My boss was great, could not be better. I learnt a lot in that year not only because he taught me so well but also because when he was on holiday I had sole responsibility. I think it was AUgust when he was away and the sobig virus hit! (or one of them that caused a lot of damage!).
I did everything out there. Backups, email, servers, networking, Oracle right down to basic user training and support.
I think I earned $12 an hour and $18 and hour with overtime. I did a lot of overtime so I was very comfortable.
In New Hampshire there is no state income tax, no sales tax and all federal tax I got back as I was a student who didn't live there. Made a killing really!
The main office of the company was on South Street Massachusetts and I travelled there often. Funny thing is there are only two or three companies on south street and 4 years later i'm working for one of the other companies on South Street (i'm in the UK though). Coincidences.
Healthcare
I took out insurance. I think it as only $100 as i'm young, fit, etc.
Other points to note are that I didn't see or have a single crime committed against me. Even at work I didn't hear of a single crime. Not one. Not one mugging, robbery or car break in.
After a day at the office I used to head to the range with a colleague and shoot a variety of big guns
Pretty much everything was cheaper out there. Only thing more expensive was wine.
People were very friendly and warm. Girls love the accent.
I found it weird that work began at 8am and finished at 5.30.
I think those are the main points. I wouldn't worry about costs. Do it for the experience - as long as you get paid you'll be fine. I can add some pics if you want to see stuff.......