A filler piece approximately 13/16" wide and 13-1/8" long was cut, fitted, and tacked into place.
After fitting a triangular shaped piece to the far end and a lot of fitting, welding, and grinding, the modification to the one side was complete. The same process was repeated on the other side.
A side by side comparison of a stock support (on the right) and the modified support (on the left) shows the reinforced bottom corners and the wider section which extends up about 2/3 the height of the support.
About one more day of modifications and the support should be ready for a test fit. I am really hoping the fire wall will not require modification to make all this fit. I am getting close.
The front side cut will extend only to the first tape. When the flange is recessed, it will not drop into the the area between the cut tape and the cross tape enough for the angle to cause problems. The extra distance will aid in bolting the inner fenders and the horn baffles.
The second photo was taken after the scoring and cutting were completed.
Finally, the side was bent out to be perpendicular to the mounting flange.
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.
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.
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.