radiator modification

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So I'm working on this project, Major modifications to a Mazda RX7.Big Single turbo with all the supporting mods.I go to install the large "stock mount intercooler" and It just isn't working for me.doesn't really fit right and the ductwork just seems like it would block too much air through the radiator. (you can search these terms and find bunches of images from othe projects)After getting this far I decide to switch gears and go with a Vmount configuration.This means I need to reconfigure the radiator.I was a little concerned, after all the radiator is welded together, but the core is brazed. Did I need to take any special precautions? So I posted questions here and on several other forums.Well I didn't get a lot of encouragement. But noone gave me good enough reason not to try.So I dove in.Here's what I started withFirst step was to cut off one side of the top tank.I cut out the new piece from 1/16" 3003 sheetthen shaped it to fitPart of the reconfiguration included making a baffle to create a dual pass configurationcontinued---------Don't talk about it, Just do it!
Reply:I dont have direct pictures but somewhere along the line I cut out the old necks. So I had to cut out and shape pieces to fill in those gapsThen I welded it upHere you can see the baffle inside the welded up tankAnd this is the radiator with the new necks, You can also see the plate with the mounting boss welded to the side.I also had to build a frame to mount the radiatorI'm still working on the final fit-up so stay tuned for more.Don't talk about it, Just do it!
Reply:You should be good, it looks like you left plenty of butter pass to weld onto without getting too close to the core. Just make sure that the welds from the pan to the butter pass are fully penetrated. Usually I'll do 2 passes on something like that, full pen and then a cover to fill it up and make it pretty. If it's not fully penetrated the heat cycles could cause it to crack. Also did you use 4043? I weld aluminum heat exchangers on military aircraft, if you have any questions PM me.
Reply:Thanks for the encouragementI did in fact use 4043 filler because it looked like there could be issues using 5056 in this application. Sent from my iPhone using TapatalkDon't talk about it, Just do it!
Reply:I know this is an older thread, but doing mods like that is the exact thing that my workplace does everyday. nice job nice welds! the more you are able weld the "un-weldable" the better .TOOLS AND TOYSSMAW Mid States Inc. "MISSING LINK" 10-150 AMP Buzzer circa 1945ishSMAW Magic Wand 40-60 AMP Suitcase Buzzer circa 1939ishGMAW Hobart 210 IronmanOxy-Propane TorchMany other old and cold goodies"Rusty but Trusty"