90 aluminum radiator swap

[6 speed 90]

Well I'm sure somebody has done this multiple times, but I thought I would share mine.

My 90 W350's radiator always leaked a little bit until the other day, it decided it didn't like to hold coolant anymore. I looked a lot of places for radiators, the problem is they all wanted $275+ for a factory 91.5 up intercooled radiator.

I didn't want to go modifying the coolant/thermostat housing and have the hose running across, also being as I have plans to push my VE pump to its fullest potential I figured a better radiator was in line.

I picked this up at Lefthander Chassis 30 minutes from me, $200 later I got a 31x19x7 dual pass radiator.

Its a quality piece at a good price, the inlet and outlet are passenger side like my stock one.

I've got it marked and I am gonna tig mounting tabs on it to use factory mounts. You will notice the outlet is facing inward instead of out like factory, I'm going to cut it and rotate 180° reweld and it will line up perfectly. I will post pictures up of it when I get to it tomorrow, and post more of the install.

 

[6 speed 90]

Mind you I know there are other options out there, but this is and always has been a budget build.

 

[Mooner1]

Cool thread man & looks sweet! I'll be following. Been thinking about doing the same on some of my 1st gens. Payed $120 to a local cat down in Ponca City to dip and go over two of my stockers but wasn't real satisfied with the work. After mounting fans and all I think I'd been money ahead to put the time/money/effort into a nice aluminum piece like this. Some folks prefer a good 'ol brass radiator but man, those aluminum radiators make the associated fab work so much easier.

 

[6 speed 90]

Yeah they get a pretty penny for checking and dipping these things, heck a recore is 500+ then your still stuck with a not real good factory unit. I agree with you money ahead just to go this route with aluminum, easy fab work too if you ever need to change things around.

 

[6 speed 90]

Got the tabs about how I want them, I will round the edges of the tabs after they're solid. Now I cut the outlet and get that how I want it.

 

[oldestof11]

Got one like that but for an IC model??

 

[6 speed 90]

Got one like that but for an IC model??

Are you you looking for a drivers inlet? They have drivers inlet. Mine fits perfect with a first gen IC, got to space it out with the thicker core. I'll post how I did mine up in awhile.

 

[oldestof11]

Yep. Thanks man.

 

[6 speed 90]

Got it welded up

Had to angle the bottom tab to catch the mount hole and miss the outlet.

Angled the bottom outlet out and rewelded.

I've got to drill holes and round the tab corners yet. Once that's done bolt it in and done.

Welded the tabs all the way around to keep them from cracking.

 

[6 speed 90]

I'm not real good with tig, but I think it'll hold

Got it test fitted, took my IC pipes off for room to maneuver it in. I've got rubber bushings to go on all 4 bolts, they measure 3/4 long to space the radiator correctly.

Here's a picture to show the room between the clutch and 3 inch core radiator, its 3/4 inch of room so not to close. I'll get better pictures of the hoses and stuff tomorrow.

I forgot to mention this is an intercooled truck in the beginning, the place I bought this radiator has one that matches 91.5 up trucks also (Top inlet drivers side) style. This truck has had the non IC radiator in it since I bought it, for ease of replacement (its my DD) I went this route.
Sorry about the crappy pictures, my rented shop space is full so I'm doing this in my garage. Not much room and minimal tools.

 

[jimbo486]

Nice work! Looks good too!

 

[6 speed 90]

Thanks! I try anyways. I'll get more pictures tomorrow, I got busy with work today. I didn't got a shroud made up yet, I've started work on one out aluminum.

I'm not to worried right now being as its winter, hard enough to get a Cummins up to temp anyways...

 

[thrashingcows]

Thanks! I try anyways. I'll get more pictures tomorrow, I got busy with work today. I didn't got a shroud made up yet, I've started work on one out aluminum.

I'm not to worried right now being as its winter, hard enough to get a Cummins up to temp anyways...

I ran my crewcab with the stock non-IC rad, 2nd Gen fan and clutch, and no shroud for about 2 years....never had any problem with cooling.

But having said that I would still always recommend a shroud.

 

[6 speed 90]

Yeah. I like them for the protection side of things.

 

[6 speed 90]

Update.... Well I've been driving the truck everyday 125 mile round trip to work. the radiator works great the rubber mounts have stay tight.

While I had my radiator out I checked all my pulleys, found my water pump was about to go. So I replaced it with an OEM pump, hoses and new clamps..
I'll get a bunch more pictures of the radiator tomorrow, I get some to show the clearances and how it all fits with the IC.

Got my wisdom teeth out so I've been recovering.:nail::badidea: But I'll be out and about tomorrow.

 

[6 speed 90]

Here's a couple pictures of the lower mounts with the IC piping off.

Here is the clutch and core support clearance, there 1/4 between the core and 3/4 between the fan clutch.

The AC lines are off in the pictures but they will fit like factory.
I'm still working on fabbing a shroud out of sheet metal I'll get some pictures of that up soon.