So I have done quite a bit more over the weekend & today:
Fitted the starter motor (thanks for the bolts Zedd) & new slave cylinder
Stripped the plastic water pipes & heater pipes from the donor van
And loosely fitted, I managed to fit the plastic pipes through the existing hole in the central crossmember under the van but had to reroute the main battery cable to the starter motor, the heater pipes won't go through the same hole, but there are other holes in the crossmember they can pass through
While the dash is out I swapped the servo for a BMW E30 one which I read aids braking, it was pretty easy to do with the heater box out of the way, there is a good thread on 'the Samba' about the conversion. it only just fits.
I swapped the blower motor in the water cooled heater box then trial fitted, all the captive nuts are in place, but they are blanked off with tape.
The hole in the tunnel for the heater pipes needs modifying as the rubber grommet is larger in the watercooled vans, I am going to cut this piece out of the donor van & screw it into place as the Aircooled van hole is taller, so you can't just enlarge it.
I robbed the junction box from the donor van which is a later van 85 & fitted to the left hand side of the engine bay, I had to move the servo vacuum pipe over to the adjacent hole to get it to fit neatly. All of the engine bay terminations between the VW & Subaru loom with be made here (on Syncroandy's advice).
I couldn't wait any longer so I fitted the engine, not too bad to do just a bit of jiggling to get the holes on the engine bar to line of with the chassis, I found long bolts helped.
One problem, the slave cylinder is very close to the bulkhead, in fact the bleed nipple is rubbing & there is no way I could get a tube on to bleed the clutch, so I think I need to cut this section out, what have other people done?
lastly fitted the new coolant header tank.
Lots still to do but feel like I am making real progress, hopefully the loom will be back soon as I want to get that fitted before adding anything else to the engine bay.
Cheers
Tony