Finally got the one thing that was high on the anxiety list for this build - installing and plumbing the evaporator. It's been a comedy of errors and false starts (my fault) since I got the kit from Vintage Air two years ago. First, I didn't know about the difference between the 6 cyl and 8 cyl core support, so I got the wrong plumbing. I didn't much care for the cheesy vent outlets, so I came up with a little more retro feel. Lastly, I wanted to use a bulkhead fitting because I didn't want to cut any more holes in the firewall (I went through a lot of work to smooth the firewall). Long story even longer, I ended up using the new Aeroquip EZ clip system so I could fabricate plumbing to fit. I'm pretty happy with the results:
http://picasaweb.google.com/ChrisAurit/DropBox?authkey=A1jnYCDOUjw#5298182924998655298
http://picasaweb.google.com/ChrisAurit/DropBox?authkey=A1jnYCDOUjw#5298182976281136082
http://picasaweb.google.com/ChrisAurit/DropBox?authkey=A1jnYCDOUjw#5298183005371448434
http://picasaweb.google.com/ChrisAurit/DropBox?authkey=A1jnYCDOUjw#5298183040643413666
http://picasaweb.google.com/ChrisAurit/DropBox?authkey=A1jnYCDOUjw#5298185814051035410

Still a few things to do (ducting, fabricate a better heater control cable, o-rings in the engine compartment), but in the grand scheme of things they're pretty minor.

Back to sheet metal. UGH!