Just a final update (with images) for today. Left front guard has been shortened, reshaped and fitted up. Advised right front guard wont require quite as much work. Once mush is happy with the guards, he will fit and weld back on the new front apron. It worked out that time, effort and cost wise, it was just as cheap (and easier) to simply source a new front apron.
The images that follow are of mush and his expertise in making new but badly cast body panels fit:
Some frustrating news about my inlet manifold and header combination. Second-hand and brand new sourced inlet manifolds don't fit with my D2 Coby headers. The manifold is hitting the exhaust runners and where the manifold bolts on to the head is being a bitch (we also had to hammer out the passenger foot well to allow enough clearance for the collector). I guess sometimes you just don't know if something will work until you try it. A bit frustrating when it's so close to the cruise... Hopefully we can still get something sorted before Labour Weekend.
For now, I have sourced a new set of D1 Coby headers to test fit (can return them if they don't), just to check clearances etc. If they do, may just have to make the D1's work (in whatever way) and try sell my D2's. I am well informed that D1's suit down-draught and D2's suit side-draught, so unsure why my D2 set is being such a douche.
Will keep you all informed of progress up to Labour Weekend as best I can, gonna be a mad rush to the finish line at this stage. Guess I can be happy that at least my carb recon is pretty much done (thanks Damon), just need to be able to bolt 'em on to test

- Braasy