Just went and checked on the rust converter, and it looked like spots had re-rusted and popped "through" the converter. I can only guess that I left those areas too wet in the first instance, so i've rubbed them back with p80 and re-applied the converter (and only left it ever so slightly damp this time).
I need to get a heat gun to see if it helps with the sound deadening.
Also a set of calipers to measure/adapt the throttle body from an AU to the BMW manifold.
More text and some pictures later - for now lunchtime is over and it's time to go back to my real job.
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