Radiator Aluminum

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Major System Category: AC & Cooling System
Task: Install aluminum panels
Parts:

• Radiator Undertray
• Radiator Rear Duct

Prerequisite Tasks: Inner Wheel Wells
Additional Costs: N/A
Time Requirement: 4 hours
Date Started: July 2, 2012
Date Completed: July 7, 2012
I started working on this half way through the Inner Wheel Well assembly. The reason being these pieces need to fit together. The other reason has to do with a couple of threads I read on the forums. I have spoken of the importance of the forums, and this is a case in point.

One of the pieces for side reinforcement of the undertray. This involves riveting three pieces of metal together.

The aluminum undertray and the inner wheel wells form a three sided box around the radiator. Unlike the rear duct piece, the undertray is riveted to other pieces of aluminum. More than one builder reported that the first time the car was taken up to speed, this piece gets bent all out of shape. There is not enough strength (simply in the panel) to maintain structural integrity. The solution is very simple - a 3/4 inch angle aluminum bar riveted inside the lip. I went the extra step of running two additional pieces to reinforce the rivet points between the inner wheel wells and the understray.

Stabilize the piece with clamps.

Consideration: Reinforce the undertray lip and sides.

The undertray installed. The main reinforcement piece runs the length of the tray just inside the front lip. It is a thicker piece (1/4 inch) than the side pieces (1/8 inch).

This is piece behind the radiator duct panel. The cross members makes it difficult to get a drill  in there.

I have additional steps of coating the metal prior to installation. The other thing I have done is lay other aluminum pieces in place on the chassis. As I worked with the rear duct piece, I noted the next piece in line was going to be a bear to drill holes for once the radiator aluminum was in place. I went the extra step and pre-drilled the aluminum and the chassis. I am wondering if some of these things are easier to see, because I have the luxury of changing the height of the car via the lift.