I just read through all 40 pages of this install thread and I still haven't seen anyone having the same issues that I am. But I have gleaned some possible solutions to try. I've been talking to bryan via private email about my issues. I noticed on the 05's, owners are getting their hotside piping in fine but having small issues on the cold side. Its just the opposite for me, although I did have to remove the overflow tank to get that particular piece in.
The pipe that runs immediately from the passenger side of the core up to the 2" piping that goes to the firewall does not fit inbetween the towhook or on the outside and if it does, it gets to the point where the bumper itself will not go back on, which made me think I had to cut into the bumper itself. The black tray is off, the flange coming off the turbo connecting to the 110 pipe is sits awkwardly in the coupler just to even attempt to reach that problem pipe. I switched to a VF-52 literally a day before starting this install.
Also, do I made a gasket out of gasket paper but do I need to use rtv (the red high temp stuff as its a common application we use on new gaskets for military vehicles around tranny and engine pans when we change em out) or no? M Sprank, I've seen you offer out a lot of advice to help people. I've sent bryan pictures of what I've been fighting and multiple angles of it.