DIY Network

Honda Civic CRX: Performance Header, Radiator and Fan Tricked Out host Andrew Totolos gives this fiesty Honda more breathing room and the wherewithal to stay cool. From "Tricked Out" episode DTRK-202

(Continued from page 3)

	The new radiator and custom bracket
	PDF Download the radiator bracket diagram in .pdf format

Fabricating Radiator Brackets and Mounting the Radiator

In order to mount the new radiator, you'll have to fabricate three brackets to mount it. Find a solid point on the chassis near the mounting post and then bridge the gap with some aluminum pieces.

Tricked Out WebExtra: If you're working on a Honda CRX, like our project car, you can use the downloadable template for installing these custom brackets.

advertisement

	Figure I
	Figure J
	Figure K
	Figure L
	Figure M
	Figure N
	Figure O

• Make a paper template the same width as the aluminum pieces you're using. Use a utility knife to cut off a few pieces of paper or cardboard that are the same size as your bracket stock (figure I).

• Then set the radiator in place on the right side of the engine bay and temporarily slide the hoses on to hold it in place.

• From under the car, measure the appropriate length and work any necessary bends into your estimate.

• Then go to your workbench and mark a piece of aluminum stock with the measurements (figure J).

• Cut it to size with a hacksaw and file away any rough edges.

• Drill out the marked hole with a step-bit to allow for a rubber isolation washer.

• Test the bend against your template.

• Lock the bracket in a vice and use a rubber mallet to make the bends (figure K).

• Take the first piece back to the car and mark the mounting holes for drilling.

• Pre-drill the bracket mounting holes (figures L and M) and insert the isolation grommet into the large hole.

• Back at the car mark through the mounting holes to the radiator support. Drill pilot holes and mount the bracket with self-tapping screws (figure N).

• Use the same methods to construct the other two brackets.

• Once the brackets are in and the radiator is secure you can wire up the new fan.

• First, you'll need to rid of the casing on the new plug so that it will connect properly to the fan. Use a small screwdriver to pry apart the fan plug.

• Separate the two spade connectors, and plug the first one into the original CRX socket.

• Tape that connection individually, and then add the second connector and tape up the entire piece (figure O).

It's time to complete the modification by finishing out the plumbing and refilling with coolant.

Materials/Tools:

coolant
hose clamp

Instructions:

• Use a little bit off coolant to lubricate the hose end, and then push the lower radiator hose onto the radiator and tighten it down with a new hose clamp in place (figure P).
  

  	Installing the new radiator
  	Figure P

• The factory upper hose is too long for the thicker aftermarket radiator so trim off the extra length to prevent kinks in the line before you slide it on for good and tighten it up.

• Push the smaller overflow line onto the fitting at the radiator cap, and slide the clamp into place.

• Run the other end of the line to the overflow reservoir. Secure it to the radiator support with a wire tie in the middle. Cut it to length and attach it to the reservoir cap.

• Once all of the hoses are tightened down, fill the radiator and overflow tank with a proper mix of coolant. A 50/50 ratio of coolant to water is recommended for most vehicles.

• When the tanks are filled, start the car and let it run with the heater on high until it reaches normal operating temperature. Then shut it down and top off the overflow tank to complete the process.
  

BEFORE: The stock radiator.

AFTER: New radiator and fan installed.

BEFORE: The original header restricted air flow and robbed power.

AFTER: The new header with thermal wrap.

1 | 2 | 3 | 4

RESOURCES :

Design Engineering
www.designengineering.com

Racing Innovations, Inc.
We apologize no contact information is available.