Radiator Stone Protector

I thought I had better create a protection screen for the aluminium radiator since it probably won't take too many stones to puncture it.  I removed the number plate bar for better access, and created a frame using 16mm aluminium angle.  Once the frame was created, a friend TIG welded the corners.

The frame is bolted up through the aluminium underbody protector into rivnuts, and also fitted to the top radiator mounting frame.  I fitted stainless mech which has 5mm openings, hopefully will stop most stones without affeting too much airflow.  The mesh was bonded into the frame using CT-1.

Cylinder Head Steam Vents - Update

You may remember when I was working with the cylinder head steam vents.  I managed to install the vent pipework, however I had to modify the inlet to the expansion tank.  The braided hose couldn't expand enough to fit onto the GD supplied tank, so I had to weld on a short 6mm stainless tube to allow the hose to fit.  The photos below shows the unmodified fitment and the route of the hose.

The hose was routed under the fuel injector wires and so is a very neat install.

Bodyshell Fitted

After making sure I had done everything on the chassis, I organised for some friends to come along to lift on the body - hopefully permanently this time!

I removed the bolts from the radiator mount and held the radiator back using some bungee cords to give as much clearance at the front as possible.

Everything was ready and so it was just a case of rolling the shell outside, spinning it around the correct way, and then lowering it onto the chassis.  I obviously supervised, while the 4 others lifted and guided the shell in place.  My son was the first to sit in to try out the passenger's sitting position.

It has certainly cleared a bit of room in the garage, basically going from 2 cars down to 1.  I do now have a spare bodyshell trolley........

Once the body was lowered, I fitted the windscreen.

I then passed the ECU connector and loom in through the from bulkhead into the back of the dashboard.  It was a bit tight getting it through, however I think the finished product is very neat in the engine bay.

I then fitted the air filter prior to re-bolting the radiator mount in place.  I actually dropped the radiator from its lower mount to get the filter in.  The filter is held in place with the rubber hose and stainless jubilee clips whilst being pushed up against the body by the radiator.

An excellent milestone!

Heating & Cooling System

I managed to find some time to work on the car during my time off which has moved on quite a bit.  The weather has been excellent for October, and a lot of outside jobs have also been done which took priority.

I re-fitted the radiator which I had previously fitted the fan brackets and fan.  I cut some rubber hose for the top mount.

After initially receiving the incorrect radiator tank (I have a newer LS water pump), I have finally manged to fit it to the upper cross brace.  I set the tank on the cross brace and lined it up to the water pump using the 38mm to 32mm silicon hose.  I then marked and drilled the underside of the brace and tapped the hole to M6 and bolted it up.

I temporarily installed the air inlet pipe to be able to align the windscreen washer tank.  I checked the overhang of the bodyshell to ensure that the tank wouldn't foul, and decided that I would make the centres of the caps at even distances from the air inlet.

I ordered the stainless pack from GD for the heater matrix and also for the lower radiator hose.  The 2 x 16mm pipes have brackets pre-welded onto them for fitment on the upper cross brace.  I had to remove some of the tank brackets to permit fitment, and I used M5 button heads to fix it.

 I also used the CNC machined thermostat housing supplied by GD which I finally bolted up in the orientation that seemed to fit best.

I need to order more stainless clamps to finally fit the hoses and finally bolt in the upper cross brace.  I still require to order some 16mm hose for the heater, and figure out the final position of the heater matrix.

Radiator Cooling Fan

I have fitted the cooling fan to the aluminium radiator using the supplied stainless steel brackets.  This involved carefully drilling small holes into the aluminium frame and I used M4 stainless button head screws and nylock nuts.  The fan is a single 16" which I was told by GD that this had more flow than the twin fan option.

I am not 100% sure of the direction of flow yet, I will only find out when I connect in the wiring loom.

I will mount the radiator to the chassis once the heater pipework has been fitted to give me some room.  I am waiting on parts coming from GD, and I am going to attempt to make up my own heater pipes using stainless tubing and silicone hoses.  I will keep you posted.

Radiator Trial Fit

This morning I thought that I would test fit the radiator while waiting for information regarding the brake calliper mounting blocks.  I thought that this would give an insight for running the water hoses and pipes.  I can also mark up and mount the cooling fan.

It took a little fettling for the bottom bolt holes to line up, and also I will have to source some form of bush for the top of the radiator where it goes through the top mounts.  I believe it's just a short section of rubber hose....

I will remove it again to finalise the steering rack mounting since it will be easier access.