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04-11-2009 09:09 PM Radiator Core Support VII
The top of the radiator must be mounted about 9/16" off the rear mounting flange. The bottom needs the flange moved into the support (toward the front of the car) about 1". Using a straight edge, I estimated the crossing point should be where the blue tape is. This is approximately at the bottom of the cross brace mount.

In order to get the flange to drop into the support, the side will need to be moved to perpendicular to the flange. The square shows how much movement is needed.

Tape was used to layout the cuts. The last shot shows the rear flange. Eventually, the cut on this line will go through. For now, it will be scored to facilitate bending the side. The far right vertical (in this photo) tape indicates where the flange will cross from being recessed in the support to being moved out from the support. The other vertical tape shows where the cut will be for the side modification.



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  [Entry #179]

04-04-2009 11:27 PM Radiator Core Support VI
The stock radiator was hauled out to see where the components were located in relation to the top and bottom of the core support. The radiator cap was the same height as the top of the core support. And, as you can see, the bottom of the radiator is recessed into the core support. That is why all this work is being done, so the new radiator can recess into the support.

Once the new radiator was positioned so the cap was a little below the top of the support, the lower tank was traced on the core support. The radiator was positioned a little lower than stock because the top tank is a little larger and hood clearance could be a problem.

The support was cut to allow clearance for the tank. Now that the tank is allowed to "drop" into the support, the location of the side cuts can be determined.

Based on the forecast, it may be Wednesday or Thursday before I can get back at it.




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  [Entry #178]

04-04-2009 11:19 PM After the Lunch Break
After breaking for lunch, instead of jumping back on the core support, I had another project that needed attention.

I bought this convertible as a project car thinking the 41 would be in paint by now. Since the 41 has taken a lot longer to complete than I anticipated, I decided the drop top had to go.

So, out of the garage she came today. It is amazing how much dirt can accumulate even in a garage. The car was filthy. After a quick wash and some vacuuming, even my wife questioned whether we should get rid of it or keep it. Tough call, but she is on Craigslist now.


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  [Entry #177]

04-04-2009 11:14 PM Radiator Core Support V
The filler piece is cut and welded into the cut.

The front side piece was made and test fit. It still has to be cut to length in the first photo.

After a filler piece is cut and the complete assembly is welded and ground, the reinforcement is complete on both sides. Cutting to fit the radiator can now begin.


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  [Entry #176]

04-04-2009 11:09 PM Radiator Core Support IV
After the back piece is completely welded in, the core support is turned over and the cut is made to allow the side panel to be bent to make the inside distance between sides uniform front to back.

A picking body hammer stretches the metal to open up the cut and transition the side to nearly perpendicular to the radiator mounting flange.


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  [Entry #175]

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