I got the van back together yesterday, and drove it around today dropping off some parts for work. A few minor issues to sort, but it runs really well! Anything more than half throttle from a standstill will turn 2 of the 4 rear tyres into tyre smoke! The power steering is fantastic, although a bit "pointy" now, I will fit another castor wedge in there to try and help with this. The new big bore stainless exhaust sounds so sweet, not too noisy when you are cruising, but has a nice deep bark when you put the slipper in! Still need to fit the evaporator into the heater box and connect up the air conditioning, but other than that it is basically finished. Super happy with it!
A few pics of the finished product:
The pulleys run really close to the radiator fans! I also fitted a smaller pulley to the blower to up the boost to 10 psi
Mk3 power steering box, with hybrid Mk2/Mk5 steering column:
I needed to make an extra auxiliary wiring loom for the engine, and fitted relays to the headlights, and horn while I was at it. That is 7 micro relays, 4 mini relays and 16 fuses!
I tried to make it look as "factory" as possible, so moved the battery tray to the RH side, and fitted the original airbox (which I had to modify a little bit) to the LH side.