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View redsdad's profile Entries: 616
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04-05-2009 12:14 AM 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]

04-05-2009 12:09 AM 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]

04-05-2009 12:04 AM Radiator Core Support III
It is hard to believe that it has been 2 months. A business trip to China. New car shopping (didn't buy a thing). Fixing the wife's Sable (did I mention we didn't buy a car?). A freak snowstorm last weekend. It felt good to get back at it.

The other side of the radiator core support was reinforced this weekend. The rear piece was made and installed first.

The vertical section of the core support gets notched to allow the new piece to fit close to flush.

A small filler is used to fill the gap.


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  [Entry #174]

02-07-2009 10:13 PM Radiator Core Support II
I decided to box the area to increase the strength, compensating for what will be removed for the lower tank. I cut, broke, and shrunk a corner. After welding it in place, a small filler was welded in to tie it all together.

With the first part of the reinforcement in place, the bottom of the original support was cut. Using an assortment of body hammers, the area was stretched in order to allow room for the tank. I didn't want to do the whole side until the box in was completed. I stopped at the top of the reinforcement, but had to cut beyond in order to have the side near the desired shape. The idea is that the side, which originally sloped inward toward the front of the car will need to be approximately 90 degrees to the radiator mount face when complete.

After welding a patch into the gaping hole left from the cut and stretch of the original metal, a new corner was welded on, completing the reinforcement of the left bottom corner. I intend to modify the side before moving to the right side. I need to prove that the side can be modified before I build another corner. If I can't get the side to do what I want, it is too much work to build corners.


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  [Entry #173]

02-07-2009 07:38 PM Radiator Core Support
Awoke this AM to 60 degrees. First warm day with me not being sick. So I took down the Christmas lights.

But I did get to work on the car.

If you look back to posts 153 through 156, you will see that I have to make some mods if I want to use the Northern universal radiator if I want it to fit.

I positioned the top of the radiator so that it would clear the hood. I could have moved it up a little bit more, but I would rather have a little extra clearance in case I need to adjust things later.

At the bottom, you can see that if the tank is going to recess into the core support, it is going to have a lot of meat cut out.

At this point, I am not sure if this is going to work. The good news is that I have 3 core supports - the rusted out one that came with the car, a pristine one, and the one I am working on here which is solid but a little beat up. I figure if I can't get this to work, I will use the pristine unit and buy a much more expensive custom fit radiator.


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  [Entry #172]

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