Its been a bit since I've posted. I've been progressing slowly, typically a couple steps forward then a few backward. Here's how it looks now:
I did take everyone's advice and buy a new heater core and fan since it was exposed and will save me the misery of taking it all apart again:
Carms64, thanks for the compliments, I'm glad you have found the thread enjoyable!
Dave, I'll make sure I get it clamped down, sorry to hear about the paint issue. Nice the painter is covering it though.