Time for some more updates.
Got the old mangled passenger side fender replaced (thanks to Pinky for helping).
Old:
New (still need to swap the other trim bits):
Had an issue with the alternator pulley munching its keyways. Had one of the washers in the wrong place which let it walk off the key a bit, and thrash about. New pulley in place and installed correctly and that is dealt with.
Fixed the horn - ground wire to the steering rack had let loose.
Tweaked the contact on the washer fluid contact on the stalk.
Raised the front coils a quarter inch, now we are no longer rubbing on tight turns! Going to get an alignment this week and then get inspected.
Still need to tuck the rear bumper. Also not getting any vacuum at the fresh air flap actuator; need to investigate the vacuum distributor. I may have swapped the lines back on it wrong.
Got these in the mail:
All new barrier hoses, ferrules, and a high/low pressure switch & combination R12->R134 conversion port. I've cut the old hoses off of my lines to reuse the metal ends. Just need to finish cleaning them up and make new hoses.
Thinking about the EGT mounting; I have an idea to remove the plastic panel where my ash tray and cigarette lighter are and to make a custom gauge pod to fit the boost and EGT gauge there. That would free up a spot in the triple gauge cluster for the volt meter and also put those two important gauges in a more visible spot. I have two "cup" style holders that I could fiberglass into a panel.
Also filled up for the 2nd time and calculated mileage for the first time. 90% city driving to work, 10% beltline cruising netted approximately 41 MPG! Which is better than the previous lifetime best of 40.9 MPG @ 60 MPH, 95% highway prior to rebuild. So very happy there! Need to turn down the fuel screw a little bit as I am rolling coal at full throttle, and that should net a bit more mileage as well!
Now for a few issues I need to take care of:
Timing belt is tracking to the outer edge. I can't run with the upper cover on or it rubs. The belt is not walking off any more than this, but I do want to have it track straight so I can put the cover on.
I found this informative post of things to check into:
http://www.vwdiesel.net/forum/index.php?topic=28388.0Also can report no oil leaking from the oil pan, which is good. BUT, I have a decent leak coming from somewhere in the lower timing cover. Ugh. My mind is leaning towards intermediate shaft seal. Not looking forward to this, but if I have to end up really messing with the IP bracket mounting to get the timing belt to track right, I can deal with this at the same time.
Lastly, have a squeak from something belt driven. I think it may be the alternator. May end up picking up a spare to have anyway, and try swapping.