Got our oil cooler off yesterday - took me hour and a half to get it off which I rwas really pleased with. Did help that just done engine out rebuild a couple of weeks ago so a) all bolts / nuts not seized which makes a huge difference, b) everything had been cleaned when engine out so you see what you are doing and c) knew where everything went,etc
Gotta say, was quite in easy in the end. Only bit that slowed me down was manouevering the actual fan housing and right front tinware to actually get it out, which was a bit fiddly.
It did take me a lot longer to put back together but I was messing about with other things...Started about 10:30 and finished totally at 18:15 so still a full days work but well worth it. The massive leak I had on the cooler was because the muppet who was helping (?) me had left the spacers / washers on the bottom of the studs so when I was trying to tighten up all I was doing was tightening against the spacers and not the crankcase - d'oh!!
I therefore decided to check everything else we had done together while it was all apart and he'd also rigged the heater control flaps up wrong so they were defaulting to the closed position. Also, the left front tinware was on the wrong as overlapping instead of underlapping with the right piece. So, all in all and really successful and satisfying days work....

Thanks for everyones help with this...