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In addition to covering that unsightly hole between the bottom of the radiator and the body of the car, we had another reason for adding aluminum paneling: improved cooling. A lot of air is lost going around, so we wanted to funnel the air through the grille opening and directly into the radiator.
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Start by measuring and cutting a cardboard template.
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We decided to use an engine oil cooler with this car, so the oil cooler is set in place and the hose holes are marked on the cardboard.
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Use a small hammer to mark the underside of the template. This shows us exactly where the oil cooler hoses will come through the aluminum.
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Cut out the marked holes and check for fit.
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As you can see, we made the lower template out of several pieces of cardboard taped together. After double-checking for fit, the outline is marked on the aluminum, and out come the tin snips.
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A small hole is drilled in the aluminum for the oil lines.
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Next a hole cutter is used to make the larger hole. This cutter helps to keep the aluminum from warping and leaved a smooth edged hole.
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The opening for the oil cooler is wider than the cooler, so we designed a piece of aluminum that will fold up around the sides and give it a finished look. The finished cardboard template for the oil cooler is laid out and the finished design is scribed onto the aluminum. Then the aluminum is cut and bent to fit around the sides of the oil cooler.
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The finished project adds a lot of class and makes the car look really cool. And it even runs cooler, too!
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