Studebaker Progress

 In our last installment the turbo piping was all completed, the transmission tunnel was fabricated and installed, and I had solved a few other minor packaging issues. The next bit of fabrication I had to tackle was the cooling system. Since there were no radiators made that would fit my application (a 1954 Studebaker with a turbocharged LM7...) I had to start with a blank sheet of paper. I was able to get a universal aluminum radiator with no inlets, outlets or filler neck installed. Then I started slicing and dicing! This job presented it's own challenges and is the final packaging issue under the hood.

Here's how it went.

I started with a universal aluminum crossflow radiator. I ordered it without any inlets or radiator cap attached. Here's a shot in the early stages of building, I have already attached the upper inlet and marked the corners of the tanks for cutting.

I had to lean the radiator forward to gain fan clearance, but the hood sloped down pretty hard there. These cuts allow everything to fit under the hood.

Here's the radiator fitted with the corner patches tacked in place.

This is the completed radiator on the welding bench. I built the brackets out of .125 aluminum plate and welded them at the proper angle so the radiator will lean forward when installed. Also note the lower inlet which has been welded at an angle to clear the turbo piping, and the 1/2" NPT bung which has been welded in the passenger side tank. There was not enough room to use a normal cap on thee radiator, plus the engine sits higher than the radiator in the car. This meant I had to make an expansion tank which would also have the radiator cap and the cooling system fill point. The remote tank will have a corresponding 1/2" NPT bung that will connect to the tank on the radiator for filling and bleeding off air from the cooling system.

To make the tank I started with a piece of 4" aluminum tube and rolled a couple of beads in for style.

Next, I fabricated two end pieces and welded them to either end of the tube.

The top side got a radiator cap neck welded on, this came with the radiator when I bought it. It's made out of billet.

This is the bottom of the tank with the 1/2" NPT bung welded to it. From here I will use a combination of AN fittings and pushlock hose to get to the radiator.

I needed a bracket to  mount the tank so I laid out this dogbone shape in 1/4" aluminum plate and cut it out.

Then I found a mounting point on the firewall, figured out the angle to keep the tank level and came up with this.

This is what it looks like all welded up.

And here is the tank mocked up in place. It will e bolted to the firewall with 4 5/16 fasteners.

I made upper and lower radiator hoses out of 1.250 and 1.500 aluminum tube, here they are on the welding bench.

Here's what it all looks like from the front.

This thing is beginning to look like a plumber's nightmare!

Another pic of the radiator in place, this shows the lean I was talking about. This way I have tons of room between the turbo and the radiator.