1G Long time member on mute... but I am here now! Replacement Radiator Not Fitting

[1990talonawdtsi]

Hello,
I have been a member for many years, but I had sold my '90 Talon TSI and haven't been on much.
BUUUUT
I just got a hold of a '92 Talon (February) from the original owner. It has been in indoor storage for the last 5 years.
It is CLEAN.
Did fluid flushes. It runs great!
ALL STOCK even the radio.

Ok, if you have made it this far, I would love a quick 'please help me'...
It started getting on the warm side, turns out the radiator was partially clogged... i ordered a new Mishimoto Xline radiator, slim line fans and hoses.
The Radiator is not fitting properly. Yes i have double checked, i ordered the proper one AND that the one I received was the proper model.
The upper brackets that hold the radiator do not come close to lining up AND it rubs the condenser bolts. Anyone have any ideas?
It was also triple checked that IT IS set all the way down into the lower support bushings.
I contacted Mishimoto, they 'haven't heard' of any of the rads not fitting properly.

 

[1990TSIAWDTALON]

Same radiator here. Used it in my 90 and it was a sqeeze to get the clamps on but they go on. Now that unit is in my 92, fits fine. MitsumotoX w 2 Spals, 1 puller, 1 pusher.

 

[19Eclipse90]

I had the same issue with a Mishimoto radiator a few years back and figured people just "dealt" with it.

I purchased low profile flanged button head cap screws (similar to: https://www.mcmaster.com/92137a664) for the condenser to prevent contact there and I had to enlarge at least one of the bolt holes for at least one of the radiator mounting brackets. Also broke off one of the mounting bolts when I was removing it so removing that in addition to these other things made that easy, "direct-swap" job span a couple weeks.

Guess it's worth noting that I also replaced the bushings using this link because my bushings were pretty well gone, so that could have had a bit more to do with things not wanting to align properly: 1g Radiator Bracket Bushings

 

[AWD-Tony]

Same issue here. I used a socket and hammered it until it was in the right position.

 

[Vegas Smith]

Even my Fluidyne is REALLY hard to get on so everyone feels your pain.

 

[AWD-Tony]

Just be careful if you use my method. It's soft aluminum.

 

[1990TSIAWDTALON]

.

Guess it's worth noting that I also replaced the bushings using this link because my bushings were pretty well gone, so that could have had a bit more to do with things not wanting to align properly: 1g Radiator Bracket Bushings

We found sway bar link bushings in our GSX that we got a few months ago, in the top mounts. They hold the radiator in solid.

 

[1990talonawdtsi]

Thanks for tips folks!
I just don't see how any finagling will work tho, the existing holes don't even closely line up. I'm considering knocking out the existing rubber, getting a solid piece, cement it in and redrill new holes...

 

[Ludachris]

Looks like their dowels are just too far off on this one. Only thing you can do is modify the bushings or make some new ones with offset centers. Maybe use a technique like this:

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I probably wouldn't do metal bushings for these though.