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Well after I cooled down a bit on the busted cooler scenario - I went back down to the garage to snap some pics and start taking it all apart again.
Basically, the first pic shows how I ran the lines. The radiator support was cut to fit the lines (not shown in the pic) but you can see the cooler still fits in front of the A/C condensor just fine. I made a bracket (not shown) that mounts the new FC cooler to the old SE cooler location.
I also noticed now in the pic a little oil under the lower banjo bolt - so it would appear after sitting that I may need to tighten that line a bit more next time or replace the copper washer.
The second pic is where the oil is coming from (sorry its blurry - my digi cam's MACRO settting was complaining about lighting) - but you can see its on the opposite side from the bungs. I inspected it while it was mounted, but I'll take it completely off tomorrow for a better look.. my guess is its leaking from the backside.
BTW - that "flap" is just old paint from the previous owner who sprayed it black at some point..not bent metal.
With any luck, maybe it can be repaired at a radiator shop - otherwise, it'll be two weeks and another $100 or so to get a new cooler!
Last edited by WE3RX7; 02-04-2009 at 11:51 PM.
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