View Single Post
  #4 (permalink)  
Old 03-28-2008, 12:26 PM
crankCase crankCase is offline
Registered User
 
Join Date: Feb 2008
Location: NJ
Posts: 30
Three hole aluminum radiator part2

After draining & removing radiator w/ fan, check dimensions of lower radiator support crossmember, I used 24 13/16” width to clear a/c receiver.
Bend sheet metal into “U” 2 1/2” on a side, open end faces engine, bend up
two 1/4” tabs on top edge then trim edge to 2 1/4”. Drill two mounting holes
to match holes already in crossmember. Trim vertical edges of radiator cutout with weather stripping. Cut two pieces of vinyl tubing & split to cover radiator core bottom support “U”, install lower hose ( you'll need to stretch hose to fit). Remove fan from old radiator, line up on new radiator , marking
3 mounting bracket holes (the lower battery side mount gets the bumper) .
Place radiator in position (it'll fit) trim top edge core support “U” with weather stripping. Cut 2x4 bracket in half, measure & bend to line up with
top fan mount holes (leaving enough room for radiator expansion) you'll notice that they mount opposite from each other. Mark & drill bracket mounting holes in front radiator support panel (remove grille first). Measure & bend 1x7” strap to go around a/c receiver & line up with bottom fan mount
hole. Mark & drill hole for sheet metal screw on inner fender panel (hole #3)
Install carriage head bolts from summit kit into fan brackets you just crafted
(thread end towards engine). Trim top brackets with vinyl tubing on sides
& bolt in place. Install lower bracket w/ sheet metal screw into inner fender.
Install bumper in lower fan bracket hole, battery side. Install fan onto new
brackets with nuts & washers form kit. Adjust fan brackets so fan doesn't
come into contact with radiator but is close. Install bulb from thermal switch
in lower radiator hose “T” use RTV to seal around capillary tube. Install rest
of radiator hoses. Remove bottom pressure seal washer from new radiator
cap. Connect wiring to radiator fan & switch. Fill system w/ coolant. Turn
ignition switch to on (do not start yet), jump wires on thermal switch to
check for proper fan operation. Double check all your work. Start car & bleed system. Be filled with awe & pride at your unbelievable skills.
Attached Images
    
Reply With Quote