Mk4 #7750 Update: Radiator surround and maybe now it’s really done?

[edwardb]

I closed out the build log for my Mk4 #7750 build some weeks ago (link in my sig line) but still had one main remaining open item. The inside front radiator surround. Rather than adding to my build log, I’ll just create a new thread showing what I did. First, I’m not a huge fan of the supplied FFR pieces. They work, and certainly many have used them. But I don’t like the rivets in the body, how the quick jack mountings are exposed, and frankly I just don’t find they fit very well. Went through the same thing on my Mk3 build, and ended up making all new pieces. I used a similar design as my Mk3 for this build, with the addition of an SS mesh screen over the radiator. I used the Speedway Nomex screen on my Mk3, and was thinking of doing the same on this build. But I added a Dark Water Customs splitter to this build, and it would have been impossible to remove/replace the Nomex screen without removing the splitter since it’s intended to be a service item, although in three seasons with the Mk3 it still looked like new. Plus I just thought the SS screen would look better than the Nomex screen.

Another alternative is the Mike Everson radiator aluminum panel. A very nice piece that I’ve seen in person. But it wouldn’t have played nice with the splitter. Note the splitter is mainly cosmetic. I just like the look in the radiator opening, as opposed to the hoop. If it helps with cooling or maybe provides a little downforce in the front, so be it. But the jury is out on either of those things.

So the first thing I did was make two sides and the floor pieces. I used cardboard to find the right shapes. The bottom nose piece goes from the front edge of the radiator to wedged into the front of the body. The side pieces are similar. From the side edges of the radiator and follow the contour of the body all the way around. Note I placed them inside the quick jack mounting so all that’s hidden. Then I made pieces from aluminum undersized where they meet the body to take bulb seal. There’s a one inch right angle on the side pieces to press against the radiator side tanks. There’s a similar bend on the front piece that bolts to the front of the radiator. Actually just to the bottom of the radiator and then neatly bolts right through the Breeze lower radiator hangar. Perfect. There are brackets on each end of the floor piece to hold the side pieces. The side pieces are hold at the top by a machine screw into a nutsert in the 3/4 tube right below the hood hinge. With the bulb seal, everything is a pretty tight press-in fit and seals against the body. I also added slots to install the splitter brackets through the side pieces.

Once those pieces were done and fitted, then made the screen. The mesh is an SS screen from Pegasus Auto Racing. Their 24 x 36" sheet Medium Mesh Stainless, #6 x .035 Wire, part number 3641-24X36. I made a cardboard pattern of the exact screen/frame required. Then laid it out on a piece of MDF. First made an outline of 3/4 x 1/8 aluminum pieces from Lowes. Then stretched the screen over them. Then another outline of the same aluminum pieces over. I temporarily held them in place with JB Weld and some clamps. When dry, removed it, put rivets around, and trimmed off the screen. Turned out perfect! Then made small brackets to hold the screen in the radiator surround.

Next had all the pieces powder coated gloss black like the rest of my aluminum pieces. I was a little concerned about powder coating the SS screen. I didn’t want to fill it up and restrict airflow any more than it already might. The powder coater assured me they’ve “done this before” and kept the coating nice and thin. It really looks nice. Picked the parts up yesterday, and installed everything this morning. I’m happy with how it turned out. Pictures below. Now just a very few small details left on the build.

Last week I received my packet from the Detroit Autorama organizers. My application was accepted and I’m officially in with a spot, delivery time, etc. That’s a great show, and look forward to having my new build there. I'm entered in the "Hand Built Sports" class, same as the last time with my Mk3. Now for some pics:

Screen on board during fab:

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3066_zps00590962.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3066_zps00590962.jpg.html)

Finished screen:

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3068_zps477291fe.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3068_zps477291fe.jpg.html)

Finished pieces ready for powder coat:

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3071_zps2390594c.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3071_zps2390594c.jpg.html)

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3072_zps933a1337.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3072_zps933a1337.jpg.html)

Back from powder coat. Added FelPro gasket material along the edges that sit on the radiator tanks. Checked assembly before installing into car.

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3074_zps69d8caf4.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3074_zps69d8caf4.jpg.html)

In place (finally!) Note the flash seems to highlight the bright aluminum radiator behind the screen. In person, it’s much more subtle. You can certainly still see the radiator, but it’s nicely muted by the black screen. The screen is relatively tight, and 3/4 of an inch or so away from the fins. So should give good protection.

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3077_zpseacdf12d.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3077_zpseacdf12d.jpg.html)

Finished product with splitter in place. I like it!

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3080_zps836a0ec5.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%20Mark%204%20Roadster%20Build/Radiator%20Surround/IMG_3080_zps836a0ec5.jpg.html)

[David Hodgkins]

Wow, nicely done!

So clean...

I have a question on the 3/4 x 1/8 aluminum pieces. Did you do long sides on the back frame and short sides on the front? Just wondering how you kept the corners together.

This is a must-ad for by build(s)!

:)

[edwardb]

Wow, nicely done!

So clean...

I have a question on the 3/4 x 1/8 aluminum pieces. Did you do long sides on the back frame and short sides on the front? Just wondering how you kept the corners together.

This is a must-ad for by build(s)!

:)

Thanks! Yes, the corners are lapped exactly as you described. Then riveted through on the top corners, and bolted through on the bottom corners as these are also the lower mounting points.

[Georg]

Your build is just great! Think I was reading it already more than ten times and made myself a nice print version with more than 300 pages. Lot of inspirations for my future build which hopefully will be come true soon (still have to come over some import issues ...)
Looking forward to see more pictures and more ideas! Amazing job!
Thanks a lot, Georg from Beijing

[Jazzman]

This looks very good, I'm sure even better in person. Thanks - One more item for my build sheet!! Those lights and lower fill look great, exactly what I was thinking about but had not yet seen. What are the lights and the center section? Your color choice is stunning!!

Jazzman

[edwardb]

This looks very good, I'm sure even better in person. Thanks - One more item for my build sheet!! Those lights and lower fill look great, exactly what I was thinking about but had not yet seen. What are the lights and the center section? Your color choice is stunning!! Jazzman

Glad you like it! The driving lights and grill is a kit from Tangent Technologies, a forum vendor: http://tangentkits.com/Driving_Lights_and_Grill.php. They have a low setting, kind of like running lights, and a high setting that is much brighter fog lights. I have them wired with an ON-OFF-ON rocker switch next to the headlight switch, and tied to the headlight circuit with a relay so they only work if the headlights switch is pulled. I had them on my Mk3. Not sure how much they really add for driver visibility, but on high the car is certainly more visible to others. Plus I like the look. Not very authentic, to say the least, but kind of a custom touch that fits with the theme of both of my builds.

[WIS89]

Edward-

Great work as always! As I have mentioned before, I admire your attention to detail and the results of your hard work.

Thanks for the update, and I look forward to seeing some pictures of you on the road once the weather clears up.

Well done Sir.

Regards,

Steve

[skullandbones]

Edward,

It's hard to believe that goes into the hole in one piece! That looks very good. May have to copy that man. The stock stuff from FFR just doesn't look cool like that. It's important since it's right up front: best view of the car in my opinion.

Thanks,

WEK.

[edwardb]

Edward, It's hard to believe that goes into the hole in one piece! That looks very good. May have to copy that man. The stock stuff from FFR just doesn't look cool like that. It's important since it's right up front: best view of the car in my opinion. Thanks, WEK.

Hard to believe it goes into the hole in one piece, because it doesn't! :p Yea, had the same comment and question on the other forum, so obviously I wasn't very clear in my write-up. The pic showing the final pieces all together was just a final mock-up before the real installation. I don't like surprises, especially when working down inside the final painted body. So made sure all the holes still lined up after it was coated. Then took it back apart. To install, bottom center in first, with three machine screws along the front of the radiator and pushed against the front of the body with bulb seal. Then the two side pieces are slid in between the radiator tanks and more bulb seal against the body. One machine screw at the top into the 3/4 inch chassis tube, two machine screws at the bottom into a bracket on the center piece. Then the screen, with a machine screw in each corner into brackets. Sorry for the confusion.

FYI, the panels are all from .040 6061 aluminum, same as FFR uses. The brackets I made from mild steel. Actually they're from the radiator cooling fan mounting brackets that FFR supplies and I don't think anyone uses. I was able to harvest several fabricated parts from those pieces. The screen is made from the SS mesh I mentioned in the first post and aluminum strips from the hardware aisle at Lowes.

[riebelt]

Very cool! Nicely done. Looks like you have the screen set so you can easily remove it to clean out the bugs.
Excellent!

[edwardb]

Very cool! Nicely done. Looks like you have the screen set so you can easily remove it to clean out the bugs.
Excellent!

Hey Terry. Thanks! Can't see in any of these pics, but your mirrors are installed on this build. Also used them on my Mk3. Super quality pieces and love how they work.

[Carlos C]

Edward:

Very beautiful, and well-thought out addition to your cooling system. It definitely gives me an idea for the blower intercooler that I will be installing in my Coupe. Great work!

Carlos

[riebelt]

Hey Terry. Thanks! Can't see in any of these pics, but your mirrors are installed on this build. Also used them on my Mk3. Super quality pieces and love how they work.
Thank you so much Ed! Glad you like them.
I like the look of that splitter as well!

[michael everson]

Nice job Ed.

For those of you that don't have the tools to make your own, I sell a similar one on my web site. It can be installed in a finished car. It's reccomended that you use the Breeze lower radiator mount.
Www.replicaparts.com

Mike

[edwardb]

Nice job Ed.

For those of you that don't have the tools to make your own, I sell a similar one on my web site. It can be installed in a finished car. It's reccomended that you use the Breeze lower radiator mount.
Www.replicaparts.com Mike

Hey Mike. Thanks! I gave a shout out to your part in my initial post. Didn't exactly fit what I was trying to do. But as I said, I've seen it in person and it's a nice option. Several other of your parts on this build though. :)