In this paper we describe a design exploration methodology for clustered VLIW architectures. The central idea of this work is a set of three techniques aimed at reducing the cost of expensive inter-cluster copy operations. Instruction scheduling is performed using a list-scheduling algorithm that stores operand chains into the same register file. Functional units are assigned to clusters based on the application inter-cluster communication pattern. Finally, a careful insertion of pipeline bypasses is used to increase the number of data-dependencies that can be satisfied by pipeline register operands. Experimental results, using the SPEC95 benchmark and the IMPACT compiler, reveal a substantial reduction in the number of copies between clusters.