New Aluminum Radiator Install
 

I bought the last radiator early this month. I was told that all drop-in issues had been corrected. NOT SO!!! :eek: It is a nice raditator, but it is not a drop-in. A few issues needed to be addressed. :mad: Both fan housings needed small areas cut away for a proper fit. The areas around the drain plug and transmission cooler lines had to be ground away to allow fans to fit original position. This was especially important to passenger side fan because of upper radiator hose clearance (which has been a noted problem). The top mounting holes had to be slotted to allow for installation, as well. The driver's side fan needed area around transmission cooler line ground away and the mounting holes slotted. The radiator cap twist tabs touched the overflow hose clamp, so I ground about 1/32" from all four twist tabs on the cap--allowing very minimal clearance. After these minor mods, the radiator bolted in fine and so-far-so-good. ;) See accompanying pics for visual detail in locker.

Tom, Subafreak and I installed mine with minimal issues this past weekend. Only issue was with the lower mounting hole (that the fan slides into) on the passenger side which had to be drilled out a little to get the fan to line up correctly with the upper mounting holes.

These radiators are great! I'm definitely pleased with mine thus far! :)

-Chike

Original radiator repair
 

Oh, by the way...my original radiator was fine without leaks following a repair of an 8" crack. My first repair was a single coat of JB Weld, but the repair failed. I removed the old JB and resanded the entire area aournd the crack. Over the course of three days, I JB'ed three layers...each overlapping the other (after thorough sanding each time). I allowed a full day of dry time between layering. I did, however, expect future problems, so I bought and installed new aluminum radiator. :)

I am happy to hear you got it installed and it is working. :)

Here's an engine bay pic of my car after the PWR rad install:

http://www.subaru-svx.net/photos/fil...etkd/31399.jpg

I installed the radiator with the stock hoses, but I have used T-bar clamps to make sure things stay put.

-Chike

I don't want to get off subject but how do you get those intake manifolds to look so good. Mine are dull and corroded.

Damn, Chike! You're going to give John H. a run for his "excess" money :D
-Bill
p.s. you can't even tell that engine has ever been out of the car ;)

My manifold is actually kinda dirty in that pic. I typically clean it with a coarse rag and an all-purpose degreaser that's safe on aluminum.

This is a better pic of when my engine bay was 'clean'... ;)

http://www.subaru-svx.net/photos/fil...etkd/23836.jpg

-Chike