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Botched my radiator *ARRRGHHHH!!!!*

 
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MikeOffline
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PostPosted: Mon Jul 26, 2004 11:19 pm    Post subject: Botched my radiator *ARRRGHHHH!!!!* Reply with quote

So I finished my brackets, found some hoses, and installed my radiator and fan. Took it for a short drive and found out that the engine moves front to back more than I anticipated. My water pump shaft was the closest thing to the radiator core at about 3/16", which I figured was enough but was not. So now I have a nice hole in one of my new radiator's tubes. I will likely scrap the pusher fan and switch to a puller, and have my core welded if I can find someone skilled enough to do it.

The moral of the story: 3/16" is too close for the water pump to be to the radiator core....
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SuperRunnerOffline
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PostPosted: Tue Jul 27, 2004 10:57 am    Post subject: Reply with quote

Poor mike.

I guess a lesson to be learned. Leave clearnace between moving parts. You have no idea how much your body and frame can flex under the proper forces.

I had stuff like this happen too.

Also, mount your radiator securly. Do not let it move, it will eventually wear holes.
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MikeOffline
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PostPosted: Fri Jul 30, 2004 12:32 am    Post subject: Reply with quote

My mounts were great, just too close Sad Oh well...
Here is a pic of the damage:
http://www.webpages.uidaho.edu/~simm8647/4Runner/Radiator/Radiator%20059.jpg
Hopefully I can find a skilled welder around here.
I am still debating on whether to conver to a puller or stay with a pusher as far as a fan goes, but in terms of clearence there will be at least 5/8", probably more if I don't convert to a puller fan.

Next thing up for your forge is a waterpump housing that doesn't stick out so far Rob. It could run off the first slot on the crank pulley just like the power steering. If you make any I'll buy one Very Happy Very Happy
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PostPosted: Fri Jul 30, 2004 5:53 am    Post subject: Reply with quote

hey, just poor some of that stuff in your radiator, that should fix it, just kidding. So what is the order in which the water pump housing, crank pully and water pump pully stick out the furthest?i gotta get my dual puller fans in there and didn't really think about the water pump housing.
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MikeOffline
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PostPosted: Fri Jul 30, 2004 8:15 am    Post subject: Reply with quote

Before putting my crank pulley in the lathe, it stuck out the furthest. Afterward, it is the waterpump shaft. The water pump pulley is offset from the end of the shaft so that it does not stick out as much as the shaft does. I also removed the studs that normally are used to mount the pulley and fan, and used short bolts instead. I also trimmed the end of the pump shaft by nearly 1/4". It still sticks out the most though. The next closest thing is the thermostat housing, which actually sticks out about the same amount.
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PostPosted: Fri Jul 30, 2004 8:47 am    Post subject: Reply with quote

thanks, i'll be doin the same to get everything to fit, you got a pic of the water pump pulley? If not don't worry about it, i'll get her to work.
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MikeOffline
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PostPosted: Fri Jul 30, 2004 8:54 am    Post subject: Reply with quote

Here is a poor pic:


And here is a link to a high res pic that shows the housing and shaft fairly well
http://www.webpages.uidaho.edu/~simm8647/4Runner/Radiator/Radiator%20035.jpg
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MikeOffline
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PostPosted: Fri Jul 30, 2004 9:04 am    Post subject: Reply with quote

This one shows it pretty well too:
http://www.webpages.uidaho.edu/~simm8647/4Runner/Radiator/Radiator%20057.jpg
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SuperRunnerOffline
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PostPosted: Fri Jul 30, 2004 9:35 am    Post subject: Reply with quote

holy cow that is close.
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MikeOffline
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PostPosted: Fri Jul 30, 2004 10:03 am    Post subject: Reply with quote

No, no, it's just the angle Smile
Ok, yeah, it's close as hell. Too close in fact....
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PostPosted: Fri Jul 30, 2004 11:03 am    Post subject: Reply with quote

DAM THAT IS CLOSE, THATS PROBABLY WHAT I'LL BE LOOKIN AT WITH A VOLVO INTERCOLLER AND A STOCK SUPRA RADIATOR. MAN THATS A BEEFY RADIATOR. I GUESS YOU COULDN'T SLIDE THAT FORWARD ANYMORE WITHOUT HITTING THE VERTICAL PART OF THAT CROSSMEMBER? DID YOU HAVE TO NOTCH THE HOOD FOR YOUR RADIATOR CAP?MINE CAP IS PROBABLY 1/2' FROM THE TOP SURFACE OF MY HOOD(NOTCHED OUT OF COURSE)THANKS FOR THE PIC
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PostPosted: Fri Jul 30, 2004 11:24 am    Post subject: Reply with quote

No, I can and will slide it forward more, that is why the crossmember is notched out, for the tanks on the sides.

After it is all done (again) I will post pics.

Oh, I didn't have to notch the hood, and I don't think I'll have to with it scooted forward either.
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PostPosted: Mon Aug 09, 2004 12:18 am    Post subject: Reply with quote

The radiator is finally all done. A local shop welded the core for me for $25, and they did a great job. I have some pics posted on my site (radiator link):
http://www.webpages.uidaho.edu/~simm8647/4Runner/4Runner.htm
The engine really moves forward a lot when I get on it in a forward gear. I did some testing with a piece of cardboard between the water pump pulley and radiator core while I was looking at how far to move the radiator, and it seems as though the engine comes forward as much as about 9/16", well, more than half an inch anyway. I don't know if that is because the rubber on my mounts is worn out or what, but there it is. The radiator is great though...
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