Radiator Support

It has been a fairly quiet two weeks since my last post.  The truck is off-site getting the brackets fabricated for the seats and the drive-by-wire throttle pedal installed.  In the meantime, I worked on the radiator support and documented the process.

The radiator support was untouched since I removed it from the car in Feb.

I made note of all the wiring clips and j-nuts.  The middle support needs to be removed in order to have room for the condenser.

I mocked-up the radiator/condenser assembly and determined the modifications I need to make in order for everything to fit right.  I have to drill two 1.5" holes (that is 38mm for you metric guys) for the A/C lines as well as to make a notch so that I will be able to install the fittings.

Also, in order for the radiator to fit properly, mounting holes need to be drilled in the base of the support slightly inboard from the factory locations.  Once again 1.5" holes.

Here is a shot of the base after the main support was removed.

Here is a shot of the notched area along with the 2 - 1.5" holes.

I smoothed-up the holes and notched areas and sent the radiator support to Edmunds Metal Works for powder coating.  I ended up drilling three holes in the base of the radiator frame (had to be careful not to puncture the radiator) so that I could use some factory wire clips.  I also took this opportunity to replace the 6 AWG factory wire with 4 AWG along with some new copper ends.

Here is another view:

Opposite side.  You can see the A/C lines and their relationship to the holes in the support.  Also, what looks like a mark on the condenser is actually the background...you can see through the radiator/condenser at this angle.

Another view: