Thanks Cogs. (I'm thinking about just getting a nipple welded onto the BOV joiner pipe.)
Ok. So I tested the AC idle up VSV using the above method from the BGB, and it works fine. I also had a spare Gen 2 VSV that I tested as well and it worked fine as well. So the VSV is not faulty.
Then I tested the sensor plug using a circuit tester, and there is power there when the AC is off, but no power when the AC is on. Yep, it working in reverse!
After looking at a few wiring diagrams, it gets the signal from the AC Amplifier and then I remembered when I got the AC fixed many years ago, they said there was something faulty with the Amplifier which they 'fixed'. Yay. I have a suspicion they either wired in up incorrectly or put in a generic amplifier.
So...where to from here? And to think I just wanted to re-route a vacuum hose!
For now, I'll leave the VSV sensor unplugged which mean no air being let in or out, and work myself up into figuring out where the AC amp is located and how I'm going to fix it.