Turned up a couple of brass adapters to allow me to pressure test the stainless heater lines.
The method of joining the tubing turned out to be worth the effort, no leaks first time (yes, I was surprised too)!
But then I decided I couldn't live with the way the hoses crossed at the front and it snowballed from there... started with making a fitting that gives me a tight 90 degree elbow.
The idea was to get away with tapping the water pump in place with some grease to catch the swarf. Would have worked if I hadn't tried it with a half-buggered tap that caused the inlet on the pump to split!
So that meant the water pump had to come off after all. With easier access to the crank angle sensor I gave the bracket for that a minor skim to get the gap just right.
I was about to machine down one of the bosses on the new water pump to fit the idler pulley mounts, then decided maybe I should re-make nicer versions of the brackets. Made some measurements and 3D printed some basic oversize patterns.
Poured some aluminium. It would be overly generous to call these castings but there was just enough material to machine down...
... after far too many hours, into these. They have the spacers built in so you don't need four sets of hands to install them, weigh less, and fit without modifying the water pump.
Also made some new odd-shaped bolts. One leg of each bracket is both an original bolt hole and the mount for the pulley. The previous iterations were double-end studs that needed double-nuts to install, these have the outer hex and an inner 3/8" thread for the pulley retaining bolts.
In place without the pulleys.
And with the pulleys, also made some custom made stepped washers that locate inside the bearings.