I did most of this post somewhere over the Pacific on our way to Canada as i didn't get around to it before we left home. We are currently getting over jet lag in Vancouver.
So in the previous post I was pretty much all set to hold my breath and drill some big holes in my car as soon as I had the required equipment to hand. Like everything else so far, this proved to be more difficult than expected, specifically finding a large enough step drill - I needed a 32 mm hole - but with only a 1/4-inch hex shank to fit my right-angle drill adaptor. All the ones that were big enough seemed to have a 3/8 hex which wouldn't fit. Eventually Amazon came to the rescue, but it took quite a bit of poking around online to find what I needed.
The first hole, basically straight through the radiator support in line with the length of the car, went OK. However, the next problem arose with the second hole which is through a "return" in the radiator support and more or less in line with the width of the car. The pilot hole went OK but then it became apparent that the condensor itself was going to be in the way of the cone of the step drill before it got to the last step which is what I needed. A smarter man than me might have taken note that the instructions for drilling these holes has this as the very first step, i.e. before installing the condensor.
So, after all the hassle of getting it in, the condensor had to come out again. Then I was able to drill the second hole. I cleaned them both up with a small sandpaper roll on a pneumatic die grinder. Then I realised there wasn't enough room to safely use a spray can to touch up the bare metal on the circumference of the holes so had to go get a touch up paint pen, another delay.
After all that, I wrestled the condensor back in, hooked up the hard lines and ran them through the new holes using the supplied grommets, and put the car back together.
You can see the flange on the side of the radiator that the overflow bottle bolts to and as I expected I am going to have to modify how this fits to clear the hard lines.
Anyway, I'm about to push the button to post this from our hotel in Vancouver so that'll be it on this project for five weeks.