Well, isolating a MIG to borrow for an hour or two has turned out to be harder than anticipated, but I should be able to weld it up this weekend (knock on wood). I've started modifying the radiator and hope to have it ready for TIG welding sometime next week. This includes not only the mounts that I hacked off from the original but also a brand new mounting scheme that I'm still figuring out.
I'm thinking I'll be able to just simply construct some aluminum mounts that mimic the factory mounts; my concern however is the vibration, force, and torque applied to the radiator from different locations and conditions will eventually deform the mounting holes and result in catastrophic failure of the radiator. I have become severely paranoid about that since the last radiator mount deteriorated so quickly.
Here's a rough 3D view of what I'm considering:
As it stands, I still need to pick up some bulkhead fittings. one -4 and 2 -6 AN bulkhead fittings, and then I need to start cutting and bending the hard line to the application. I'll then be taking the lines to be flared at a hydraulics shop and fitted with the nickel AN nuts I bought recently. I'll also need to figure out the NPT size fittings for the drain petcock so I can put in a t junction to fit both the hard line and the Coolant Temp Sensor.
Speaking of which, does anyone know the thread pitch and what not for the coolant temp sensor? Pretty sure it's NPT.
I'm also probably going to begin construction of the fan shroud and mounting scheme tomorrow (hopefully I'll have the steel welding done too)... Busy, busy, busy.