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The next order contained many more parts including the cooling system components, luggage compartments, the brake system, wiring loom and lots other small bits and pieces. We decided to firstly fit the radiator in order to ‘fill up’ the gap in the front of the chassis. I assembled the radiator with corrugated card between the fans and the radiator element, in order to cause the fans to stand off the fins to avoid the fins being damaged by vibration of the fans etc. The bottom alloy plate was riveted to the radiator, and the fan wires were put through the holes. All the bolts were tightened up and the radiator was carefully lowered into position.
It immediately became apparent that we should have left space in the alloy panelling for the fitment of the radiator to the mounting points in the chassis. Frustratingly, we went back through the instructions and it did not mention this! However some foresight may have been worthwhile, since the mounting point was quite obvious! However now the problem was that the double skin kit had been installed and so we could not see where the mounting point was. We decided to guess where it was by lowering the radiator into position and seeing where the approximate position was. We did this, marked out the places where we thought the holes would be and drilled a small pilot hole, just big enough to see through, in order to check the position. This turned out to be in exactly the correct position, so we ‘biggerised’ the holes in order to fit the mountings snugly against the chassis mounts. The rubber mounts for the lower half of the radiator were quite fiddly to fit, and we found it helped to have mounted the front of the radiator first to limit movement to some extent.
Since we would be looking to put a pretty powerful engine in the car, to which cooling may be an issue, we fitted extra panelling at the sides of the radiator in order to channel air into the radiator, rather than having it escape round the sides. These panels were included in the kit, and are recommended to be fitted on cars of over 500bhp. These panels were rivetted in position in the same way that the other alloy panelling was previously, before the radiator was lowered in.
The cooling tubes were installed along the sides of the chassis after the radiator was put into place. The approximate height for the cooling tubes was taken from the height of the exit hoses from the radiator, and by measuring the P-clips supplied, we could work out what height on the chassis these were to be mounted. The pads were fitted round the inside of the P-clips, which were then slid onto the coolant tubes. The bend in these was lined up with the profile of the chassis so that the pipes were now located horizontally and vertically. The P clips were then rivetted to the chassis with 3 rivets each, making sure that the pipes were held securely. The blue Samco silicon hoses were then fitted between the radiator and the coolant using washing up liquid as a lubricant, as they were extremely tight to fit onto the radiator. The jubilee clips were tightened using a wrench (rather than the screwdriver slot) in order to get them extra tight to avoid leaks.
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