I managed to score a set of horn baffles off ebay. So, if I screw the first set up, I will have a second chance.
Tonight, the horn bracket on the left baffle was removed. It was then clamped in place to see what was going to have to happen for it to fit. Unlike the inner fender, it needs more than a slice and brake. The bottom flange will have to be broke until it is parallel to the centerline of the car and then it will have to be moved toward the outside of the car by about 5/8". This is going to be a bit trickier. Time to sleep on it.
The fenders and hood were hung on the car to see how things are going to fit together. On the whole, I probably didn't do a lot of work tonight, but what did get done sure feels good.
I haven't ordered the fan. Going to wait and see if anything turns up at the swap meet this weekend.
Regardless, the radiator stays. I just have to figure out how to make it all work.
So attention was turned to the inner fender panels. There is a bulge which had to have a relief cut so it would fold back on itself. This was made 1-5/8" back from the front edge of the panel. A cut from the front of the panel back to the relief cut was then made at the top of the bulge. Finally, the bottom portion of the flange was broke at 1-5/8" back from the front edge. The panel was then bolted to the cowl and the radiator support. A pie shaped piece will have to be cut and welded in the cut at the kick-out.
The same procedure was repeated on the other side. Bolting the second one on was a real rush. After Saturday, it feels a lot better seeing progress.
I pulled the front sheet metal off the 41 and dropped the engine and tranny in. After bolting the radiator to the core support, I tried it to see if it would fit. Unfortunately, it lacks about two inches of clearing. I don't want to modify the driver's side of the firewall. Unfortunately, that is what it would take to use the radiator / fan combo shown here.
Put the radiator in without the fan. After some measuring, it looks like a 118 Flex-a-lit will do the trick. I better get one on order.
I am the envy of my friends. My wife loves to mow the lawn. We used to fight over who got to do the mowing. I finally gave in and let her do the mowing. (Don, eat your heart out!)
So, tonight I changed the oil in it and aired up the tires so she can get after the grass.
I also finished the other side of the core support. Same technique as the other side. It went a bit quicker since I had a better idea of how to complete it.
I will finish the welds and tie up other loose ends once I am sure this will work.
I did a final fit of the radiator to make sure it will fit. The radiator is now 1-3/4" closer to the front of the car at the bottom than it was going to be with the original plan which would have spaced it 3/4" away from the support.
I will have to work on the front end of the Sable this weekend. Hopefully, I can still assemble the front suspension of the 41, drop in the engine, and then check to see if this core support modification will allow the engine to clear the fans. I have my fingers crossed.