Thanks for the tips on gently bending the condenser tubes... everything seems to be fitting OK now. You can't be afraid to tweak some parts sometimes!
Radiator and condenser are in for good now, just need to get some washers for the M6 button head screws I used. I grabbed some foam from Home Depot to help seal the condenser against the core support so hopefully that holds up.
I am now deep into my next big job which is getting the wiring figured out. My strategy so far has been to unwrap everything and loosely lay it in place. I've then been starting to connect things, and play with different layouts and how I want to route the harness. Sometimes that means shortening some wires and lengthening others. I've also been repairing any damaged wires along the way and replacing any of those crimp-on connectors with nice soldered jointed covered in heat shrink. It's taking me a long time but wiring is one thing you don't want to have to go back and do twice!
Once I have everything where I like it, I've started to wrap everything using Tessa tape. I was put onto this stuff from a local builder and I love it! I have 2 types, one for high temp areas and one for the rest of the engine bay. It's very easy to work with, and leaves a nice professional look. I've been starting at the furthest end of the harness and working my way back towards the firewall which has been working out OK for me so far.
