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View steve392's profile Entries: 226
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11-21-2010 04:12 PM Willys - Radiator & Fan
First photo shows the radiator mounted in place in the brackets. Some rubber strips will be bonded onto the inside surfaces of the brackets to cushion and support the radiator. For the side braces, I decided to use some long aluminum turnbuckle linkages mounted between the top of the side brackets and the frame. They make for a very strong mount without taking up a lot of room. Last photo shows the linkages in place. The linear actuators for the tilt will mount to the top of the frame rails just in front of the crossmember and fit between the radiator supports and tilt hinges.


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  [Entry #141]

11-21-2010 04:09 PM Willys - Radiator & Fan
The revised side brackets were installed onto the bottom bracket and bolted back onto the frame rails. I only installed one bolt on each side so that I could pivot the entire radiator/fan assembly only enough to clear the tilt shell. Once I am sure of the clearance between the top of the radiator and tilt shell, I can go ahead and drill the bracket for the second bolt. I also made a new top bracket that would clamp across the top of the radiator as well. The ends were bent just like the side brackets. Last photo shows the completed radiator support. Also seen in photo are bottom fan mounting brackets. Top brackets will be welded to top support later. It turns out that the only part of the radiator support bracket kit that I used was the bottom channel. The rest was wasted. I should have built the entire thing from scratch and saved some money.


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  [Entry #140]

11-21-2010 04:07 PM Willys - Radiator & Fan
The bottom of the bracket needed to be bent to a 90 degree angle, so I came up with a simple bending brake that I used in a bench vise. I've had success in the past bending narrow aluminum strips this way, and decided to try bending some wider stuff the same way. The first attempt at bending almost broke the vise because of the short sides of the angle bracket I was pushing against. I tried it again with a larger piece of angle for more leverage. Combined with some heat from a propane torch, the aluminum bent with little trouble. Third photo shows finished brackets.


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  [Entry #139]

11-21-2010 04:05 PM Willys - Radiator & Fan
The support bracket kit that I got came with two small top brackets that mount to the radiator which in turn mount to side braces. The side brace material supplied was just a piece of 1/8" aluminum stock that needed to be cut and fit as required. After studying the layout for a while, and fitting the tilt shell back on to check clearances, I decided to scrap the supplied top brackets and side braces. I just didn't like the looks of any of it. Even parts of the lower bracket that bolt to the frame rails were scrapped.
Instead, I decided to go with full-length side and top brackets that would completely surround the radiator giving it more support, and also look a lot better. I designed new side brackets and cut them out of 1/8" aluminum.



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  [Entry #138]

11-21-2010 04:03 PM Willys - Radiator & Fan
The next step was to mock-up the radiator support bracket and finalize the radiator location. The bottom support bracket gets bolted to the inside of each frame rail. Because of the total depth of the radiator/fan assembly, it was necessary to move it far enough forward that half of the bracket extended out past the end of the rails. I made two small angle bracket extensions to support the rest of the radiator bracket. Last photo shows the radiator bracket installed. The radiator is tilted back slightly in order to clear the tilt shell.


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  [Entry #137]

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