PART 1 CHEVY C10 RADIATOR SUPPORT BUILD | Aluminum 73-87 C10 Upper Radiator Support Bracket

Ok guys, got another project here On the old C10 Still kinda working on the cooling system a little bit.


Ok guys, got another project here On the old C10 Still kinda working on the cooling system
a little bit What we’re doing now And I’ve alluded to this in a previous videos We’re going to be making a plate That’s going to hold down the radiator So we’ve made some modifications There’s a series, there’s a 2 part series
of videos Where I made the fan shroud And I’ll pop a card up here so you can check
that out Also, another 2 part series here on the coolant
reservoir And again, I’ll pop a card up here And you guys can check those out They should open in a separate window So if you want to open those up and Continue watching this or flip around Whatever floats your boat, go for it So in this video we are Like I said, making the plate That’s going to hold the radiator in place So I’ve got some material for it I’ve got 2 pieces 1/8” 6061 aluminum These are what my metal store calls “drop” Other places would call it “rem” For “remnant” or “remainder” These are just cut pieces from somebody else’s
order And they sell it cheaper They sell it by the pound basically And then I’ve got some bungs And I’ve showed you these before I’ve kind of alluded to these in the coolant
reservoir video They are from Bung King I’ve got 2 different kinds We’ve got a steel weld in bung Fairly small little thing It’s an open ended bung Then we have these aluminum ones Now these are blind So they don’t have a through hole And these are also 6061 I’m not sure what the grade I imagine just mild steel Something like that Both are for 3/8” coarse thread hardware So 3/8” diameter, 16 threads per inch So we have those We’ve got our material So let’s just go ahead and get started The cooling system has been drained I’ve already drained it And I’ve had it… I’ve had the radiator in and out doing some
other things And I’ll show you that I’ll actually post it up right now Some still photos These are brackets that I made To kind of raise up the radiator And the reason I did that was because On this truck… The inline 6 is actually fairly tall And so my radiator cap was actually lower Than my water outlet So I was getting an air bubble in there So these are the brackets that I fabricated They’re just simple aluminum brackets They were 0.080” thick material The same material… The leftover material that I had from the
fan shroud build So there’s no video for those… For making those little brackets Those little risers No video for that, just photos All the photos are on my Facebook page And you can go check that out And again I’ll pop a little card up here Hopefully it’ll work Hopefully it’ll link you over to my Facebook
page But again, no videos on making those little
riser brackets Strictly photos So, the radiator’s in I’m going to leave it in right now We’re just gonna go ahead and get started There’s a few pieces that I’m going to
make to begin with And then eventually we will have to take it
out And then I’ll show you where all these These little bungs and everything will get
welded in to So, let’s get the saw and get everything
set up here On the workbench And get going on this Ok, so the first piece we’re going to make Is actually going to go right on top of the
radiator here itself It’s going to be close to the top of the
radiator core But not… Not flush Not sitting on it So it’s going to go across like this Roughly at about these 2 points here We’ll kick it up And then kick it flat again And that flat area That’s where I’m going to be mounting These radiator support pads This one is kinda rough looking I should probably get online and order some
new ones I’ve been looking around online through My local auto parts stores Nobody seems to carry these but Several of the vendors The online vendors that I’ve used before Do carry these So I’ll get online I’ll order up some new ones of those But, first piece, flat across here Kick up, kick back flat And so that’s what we’ll make We’ll get everything set up on the workbench Make a few cuts and a few bends And get this piece fitted Alright, I’ve been over at the truck doing
some measuring And we’re going to start our first bend An inch and three quarters back From the edge of the material So… just make sure all this is tight So we’re doing kind of a dogleg bend here And the rise of the bend itself Going from kind of close to the radiator Up to that support pad Is only a 1/2” So we’re not going to put a lot of angle Into these bends So lets go ahead and hammer this one over Alright, let’s go with that Alright, so this little portion needs to be Roughly an inch in length Clamp that down Double check my measurement again Alright… still good Put another clamp on there And we’ll hammer this over Alright… that should be good So let’s take it out and check it Not bad Looks alright Without the other side being bent it’s hard
to tell Let’s do one thing Let’s at least check that rise Or that drop… however you want to look at
it Let’s see how much we’ve got That’s showing 7/16” Which is good We were kind of looking for about a 1/2” So we’re only a 1/16” shy there Same on that side So it’s even all the way across Which is always good So, let’s just bend up the other side Of this material And then come back and test fit it Alright, so I’ve got both sides bent up
here So let’s give it a test fit So if I push down on each end Oh wow… we’ve got at least a 1/4” Between the plate and the radiator Flexes, but it’s not going to do that Cause we’ve got several more pieces That we need to add here Now I’m actually… With the fan shroud project and The coolant reservoir project I’ve pretty much tried to bend it as much
as I can Now, I’ve bent this material But I’m probably not going to try and bend
anything lengthwise It’s a little bit thicker And it’s a little bit more difficult to
do This is just… This is 3 and 1/4” So this cross section is not much To be able to bend over Something that narrow But… something that’s 30” long Like this Trying to bend it over Think I’m going to try and avoid that So, we’ll be doing a lot more welding On this project than we did with the Fan shroud or the coolant reservoir So, this piece fits pretty good So, we’ll move on And we’ve got to make a piece that goes
down like that We’ve got to make a piece that goes on top
here And another piece that kinda goes In that manner right there So, let me get the tape measure out And we’ll keep going Ok, we’re ready to make out next piece One thing that I wanted to point out right
away I pulled the wiring harness away from this
area right here It’s actually just kinda hanging down here In the wheel well a little bit It was in the way And really all it was Was plugs for the lights and Little circuit breaker over here for the electric
fan But this is the piece we’re going to make It’s going to go down, like that So we’ve got an overall length here of 29
and 7/8” So that’s going to be our length That we’re going to need to cut And I’m thinking I’m thinking 3” down is what we want Cause there’s going to be a little bit cut
off Because like I said, I have a little bit of a hard time Trying to make a real straight cut with the
jig saw But I can make a real straight cut with the
band saw So there will be a little bit cut off Of the crooked cut So it will probably be something like 2 and
3/4” Which is fine That’s plenty So, let’s move over to the workbench And cut out our next piece Alright, one other thing I did off camera Is I built a little fence On the bandsaw To straighten out this edge right here This was the jigsaw cut we made for the first
piece So I made a fence This edge right here, is a sheered edge From the metal store So I know it’s at least straight It’s not necessarily square with the end Or anything like that I haven’t checked But that’s not really important As long as these lines are parallel As long as I get a straight line This is the little piece that I cut off At it’s thickest it’s maybe a 1/4” Then at it’s thinnest it’s about an 1/8” But… that’s junk Don’t need that anymore So, I said 29 and 7/8” But the other one was 30” So we’re just going to go ahead and cut
it 30” And trim off a little bit The little bit that I will need to trim off So we’ll measure this out and get this cut Alright, lets try this Well, we’ve got interference With the radiator hose on this side And this little plug I made It’s a heater hose kinda plug So, we’re just going to have to cut an angle In each side to gain some clearance there So I’ll probably just… May not be 45 It may be 25 to 30 degree angle there Something like that So let me look at it a little bit more Make some marks, make some cuts And then we’ll come back Alright, so I made a cut on each side 35 degrees, I think that will work And yeah, I think that’s going to work Now what I actually have to do Is you can see the fan here Basically, I want this… This piece, to be flush against this piece This edge right there Actually, it will be this edge That I want the top of this to be flush with So we’ll also have to cut some material
off there But for right now we’ve got to make A little bit of a radius We’ve got to allow some room To drop this down So we’ve got to make a cut in here Basically the radius of the fan To follow that curve So… That looks pretty good there And there So I’m going to get a centerline here Right there And a measurement Let’s go inch and a quarter So, let me go set this up of the workbench And we’ll draw out our radius Alright, here’s the mark that I made When I was mocking it up on the truck itself I extended that mark up Made another mark there That’s that inch and a quarter Of depth that we want this to kinda go down So I measured the fan It’s a 16” electric fan But there’s some shrouding around there So the actual… The true outside diameter is not 16” It’s really closer to about 17” So, basically I’m going to do an 8.5”
radius So I’m going to set my 8.5” on that line Then come right here And I’m going to hammer a nail into my workbench Not deep Just fairly shallow so I can pull it out easily I’ve got some 1/16” Aluminum TIG filler rod I’m going to go to there Right at that point I’ll bend it over I could measure this out just as easily But works either way Alright… So we’ve got that Not sure if you can see… Yeah you can see there’s a clamp right there This piece of aluminum is… Clamped to the table So we set our Sharpie in there And just sweep From side
to side And there we go We have our mark To cut out Alright, last thing I want to do The fan shroud… Or I should say the shroud around the electric
fan Not the one on the whole radiator But the shroud, the plastic shroud around
the whole electric fan Right up here, where this piece is going to
slide over It’s actually flat across there And I measured it out It’s 5” from the center line So we’ll just set our scale at 5” I’m sorry, set the centerline at 2.5” Where it intersects over here at zero And where it intersects over here at 5” Just draw a line across That’s about 7/8” Right on 7/8” So we know that line is straight So we’re not going to cut this up here We’re just going to cut all this right here Kinda curve there Straight across there And curve down Just to follow the lines of that electric
fan Ok, hopefully you can see this little flat
area See if I can get that wire out of the way Maybe that will clear it up But there is a little flat area right there So let’s give this a test fit Flush there… Flush on that side That fit’s pretty damn good I like it So we’ll take these two pieces off I’m going to set these up on the workbench To draw this line right there For this little bit of material that we need
to Cut out from this little dipped area So, we’ll take these out And go draw that out on the bench Alright, so… Let’s get this drawn up We’re corner to corner there Ok that looks good there And I think this piece right here Has a little bit of a bow to it I mean it’s easy to bend out of there It’s just, you know… We’ll fix that when we weld this all But I want to check the depth there That’s 7/16” And that’s also 7/16” And you’ll remember when we did the… Measured our bend like that That was 7/16” So, if I come here to the center We’re at 5/16” So, I’m going to measure off 7/16” Actually, first thing I’m going to do Is draw in Each corner Like that And then We’ll just connect the dots And make sure we’ve got a straight line
here Without any bow in it or anything like that Alright, lets test it with our other piece That…. Looks pretty good So… I’ve got the welder set up in the garage So I’m actually going to prep this material And go put some tack welds on it I’m not going to fully weld everything But I am going to go And put a few tack welds on it So let me get this prepped Jigged up And then we’ll go put some tacks on it

8 thoughts on “PART 1 CHEVY C10 RADIATOR SUPPORT BUILD | Aluminum 73-87 C10 Upper Radiator Support Bracket”

  1. Good job with fabrication on this job too! Parts are getting hard to find on these good ole trucks which are far better than the new "cookie-cutter" manufactured trucks. A sheetmetal brake would be nice to have. 🙂 Thanks for the video.

  2. If you Choose Check out Genesis auto parts they sell the Aluminum Radiator's for a GOOD price, They are probably from China but for a Economic Build they should be ok. Have you ever thought of adding fuel injection to the Old Inline 6 maybe a GM TBI system??

  3. Am not a welder at all but I am learning, did you clean the aluminum before you started welding ? Aluminum is very picky when doing tig.

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