My son and I had been working on his cooling system (see: Radiation Overload) attempting to get the radiator mounted into the radiator core. At first we were going to put it behind the front brace (the angle iron we affixed in place of the top core support portion). We figured out a little bit later into the build we wouldn’t be able to do this because the radiator would be sitting too close to the engine for the hoses to get run correctly. To deal with this, we decided to place the radiator in front of the angle iron. This allows us to put the electric fans between the radiator and the engine, as well as getting the hoses an easier run between the two.
It’s hard to tell in the following pictures, but there is now a ton of room between the engine and the fans. I’ve already mounted the fans on the radiator, which should work just fine.
While the son was here over Christmas break, I also made the tabs and welded them to the bottom core support. While it’s not a perfect job, the overall effort turned out well. The tabs are solid and support the radiator without an issue.
Here’s what the radiator looks like with the fans attached to it.
I had stated previously I was tapping the angle iron which is being used for the upper core support and had broken the tap trying to make it happen. I went to Lowe’s this morning and picked up a new 1/4-20 tap. This one had the correct drill bit with it (I couldn’t find the tap by itself) so I worked the holes a little bit with the drill, then ran the tap through them which worked rather nicely. Previously I had bought some new rubber snubbers which I was able to mount directly into the mounting tab on top of the radiator. I used some stainless 1/4-20 allen head bolts with flat washers to run through the angle iron. Here’s what the upper part looks like with all of it together.
My son and I mocked up the front end prior to his leaving. We needed to trim up the bumper to allow it to fit. Here’s what the whole shooting match looks like together.
I had previously created a bracket and placed the coolant reservoir in where the A/C compressor used to be on the engine. It was a great fit … unfortunately it isn’t going to work. Even with the extra clearance the JDM hood provides, the VW ball sits about a 1/2″ too high which means it’s going to have to move. I thought I would include a pic of what it looks like installed so you can see part of my handywork.
The alternative we are going to go for is purchasing a battery relocation kit to move the battery to the trunk. This will give us room to put the reservoir and the charcoal canister in its place and low enough so they are both out of the road. Yes, that’ll mean I’ll have to create another bracket or modify this one so it will hold the ball, but so is the life of fabrication. I know Nik Blackhurst from Bad Obsession Motorsport knows this all too well. I just wish I had a smidge of his talents!