Fabricating an Upper Radiator Mount.

After installing a Mustang radiator in my Torino I couldn't use my upper radiator mount. The new radiator is wider but shorter than the original. So the new radiator was too short to use my stock mount. I doubt that there will be many doing this exact mount. I'm just hoping some of these techniques will be useful.


The first step is to determine what I want the bracket to look like. So I made it out of a manila folder and reused painters tape.


I wanted to use the original rubber parts though. That allows me to order new ones later and the stock rubber pieces have nipples that prevent them from moving around. I also put them on the radiator to see if they would form into a good shape.




The first pieces to be made are the strips that hold the rubber. I measured 1" and the smashed portion of them was 1.25". So I made the strips 1.25" X 4" out of 18ga steel. The original appears to be 16ga. So a good shape is important.


I laid out the grid at the center and ±1.5", the distances to the nipples. The holes were drilled to allow the nipples though.




To form the top of the radiator I wanted an arc. I put a piece of folder at the end and laid a fine point marker down and moved it across on its side to transfer the shape. I cut it out and verified I got it right.


Then I ran the pieces through my combo roller. It gives a nice arc but isn't completely necessary for this piece because similar results can be had by had bending. Then test fit with the rubber in place. It is good except were the rubber was smashed, so this is good.






I started thinking about how the arms coming down were in my first template and wanted to reinforce them. I decided to break it up into three parts, the cross piece and the two arms. I redesigned the arm to include bends that will stiffen them up. I added to the template then made a new template. I cutout the big pieces on the shear and hand cut them to the shape of the template.






I used a vise and two scrap 1/2" square tubing to make the tabs. The square tubing gives a radius to the bend I find a little better looking than the sharper bend of a brake. Clamp the piece in the vise between tubing with the line just below the tops of the tubing. Then I hammered the flange down by going from one end to the other a couple of times until it is completely hammered down. Then I bent the other side of the arm. The bends in the second arm are the opposite of the first.










The next step was to tack the pieces I had together. I put them side-by-side to ensure they were as close as possible to each other. Then another test fit. Once I was satisfied with the fit I weld the rest of the seams with small welds. I didn't run a bead.


I don't have picture of this step. I put the arms on the radiator and marked were they met the corner of the radiator support frame. Then I hammered that portion of the flanges flat and bent them down in the vise. I trimmed the end to clear the hood latch bracket and drilled the holes about were the U-nuts are. Then another test fit.


I took the remaining piece of my template and cut it out to shape. I ran a hammer on the front and back edges to create a small flange, bending the pieces between the arms to 90*. Then another test fit. I scribed where the pieces met.




I drilled the holes in the cross piece to match were the holes in the arms and trimmed the excess material leaving 1/8" to bend as a flange. Then ... yes, another test fit, this time with the bolts. At this point I decided to bend the end of the arms down to better follow the radiator because of where the arc ended up.






All three pieces get a round in the vise for initial filing. I file when I can because I find it less aggressive than a grinder and cutting disks. It also allows me to get to know the final piece.


After filing, the pieces get assemble, clamped and weld together. Test fit, again. Then final filings to ensure the edges were dressed and the corners knocked off.






Painted and installed.

Amazing what you can do with time, hands and a small assorment of tools....

Nicely done!

Shawn,
Couldn't you just order one of those? Just kidding, that was awesome handi-work and you told it perfect pictorial fashion. Nice little project and thanks for taking the time to document it all here. Sweet job on all the little radiused edges.
Jon

Thanks, all.

Originally Posted by Mikelonis

Shawn,
Couldn't you just order one of those? Just kidding, that was awesome handi-work and you told it perfect pictorial fashion. Nice little project and thanks for taking the time to document it all here. Sweet job on all the little radiused edges.
Jon

Thanks Jon,
I've learned that pictures can be much better than memory. So that why I take pictures of just about everything. You know, pictures are worth a thousand posts. Making an article out of it is just a great way to share it. If anyone gets anything from it, awesome. I've learned allot from others article, so why not reciprocate?

As far as the radiusing the bends go, I have to give credit and thanks to Ron Covell and his videos. Welcome To Covell.biz I got a few when they clearanced the VHS. I really like his teaching style. To do him justice, I should have made a buck to hammer form the pieces right. I guess I'm just happy that the piece came out so well.

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I'm in awe. Tasty!