Radiator Swap: XF Falcon
Into A Mk3
By Alan Martin
After
recently splitting the radiator in the MKIII I visited the local Repairer to be
given a “guesstimate” of around $450 for a recore job and, I would have to find
good tanks for him to work with.
When I got
home I had a look at the RECO XF Falcon radiator I had and did some
measurements. Whilst the size and shape differ greatly it was clear that I
could make it fit with some relatively minor surgery.
The XF
radiator is a cross flow type therefore the opening in the MKIII support panel
does not need to be modified. The coolant flows horizontally across the opening
and the airflow can spread across the face of the core as the radiator is
mounted back from the panel by approx 50mm (2”).
The XF
Radiator will not sit down between the rails as the Zephyr one does therefore
some surgery will be needed. Although it would be possible if you are prepared
to channel the front of the rails.
As the
lower section of the support panel tapers toward the engine it will need to be
cut and bent forward in line with the panels face. This will give enough
clearance for the new unit to sit low enough to clear the bonnet.
Make an
L-shaped cut along the bottom of the panel and upwards adjacent to the inner
guard and then bend the panel into the vertical position.
Whilst
doing this have a look at the top edge of the cross member between the rails
and see if it will foul on the bottom of the radiator, With this particular
radiator I needed to “flatten” that out for clearance for the lower radiator
mounts.
BE
CAREFUL OF THE L/HAND BRAKE LINE.
I made use
of the factory mounts by attaching them to a length of right angle and fixing
it to the rails as shown. If I was to do another one of these swaps I would
most probably use a length of 50mm steel angle and weld it to the rails.
It is also
possible to bolt the mounts directly onto the lower part of the radiator
support panel for a better finish.
Cut outs to make way for the top of
the tanks and the mounts.
Again
making use of the factory mounts I made up flat plates which are tech screwed
into the back of the bonnet lock panel. These brackets don’t look very pleasing
and I do plan to make a neater factory looking set up as soon as possible.
As the
outlets on the Falcon are opposite to those of the Zephyr some tricky plumbing
is required. The top hose was quite simple as the clever engineers at ENFO designed
an outlet that rotates 90 degrees allowing for any reasonably straight short
hose to be used, although I used a multi fit one of approximately 350mm.
The bottom
hoses needed a bit more work as I could not find any factory hoses which would
neatly fit. I then had the local exhaust shop bend a piece of pipe up use as a
cross over pipe and I then fitted a multi fit hose to one end and a XB Falcon
V8 bottom hose to the other end.
I went to
the local haberdashery and got a length of thick walled cardboard tube (from
inside the fabric rolls) which I cut and taped to shape for the pipe bender to
work off.
The
straight part of the pipe is currently “mounted” to the lower cross member with
cable ties but I intend to have tabs welded to the pipe which can be bolted
directly to the length of right angle. The bend of the pipe will be dictated by
the shape of the hoses you manage to find. A simple straight pipe with a bend
of around 45 degrees should be enough. And using multi fit hoses makes it even
easier.
SUMMARY
Some of
the advantages of this modification are obvious, such as availability and cost
of cross flow radiators. In fact most of the “new” cars I looked at had very
similar size and style radiators to this one and were available quite cheaply.
Also the cross flow type of unit is more efficient that the old type and can be
patched if need be. Most of these radiators are already set up for thematic
fans. They also have tanks which are not welded on so the average bloke can
have a go at unpicking a replacement tank off a cheap wrecked unit for use on a
good one with a split tank.
The cost
of this conversion came in at under $100, not including the Radiator. The
mounts cost $20 from the wreckers and the hoses were around $60. The rest of
the bits and pieces like the aluminium angle and tech screws were obtained from
the local hardware store for approx $20.
NOTE: It
was also necessary to relocate the starter solenoid to the inner guard as the
radiator was too wide for it to be located as factory.
Disclaimer:
The advice and guidelines given in these articles are given in good faith.
The owners and managers of the Galeforce Zephyr site will take no
responsibility for any injuries or loss sustained while carrying out the
described tasks and procedures or any consequences arising. Please read
the Safety
First Article