radiator core support

[williambogner]

How hard of a job is it to replace the radiator core support. Entire assembly. Does it involve any cutting,welding? If so can you post pics of the jobs done, thanks

 

[2qik4u]

i dont have pics but the job isnt that hard to do. yes it requires welding and cutting but the cutting is done with a drill and a spot weld cutter. the spot weld cutter is similar to a hole saw. remove front bumber, headlights, radiator, and anything else that is attached to core support. you will see around the perimeter of the support are small indentions where the factory used a resistance welder to squeeze and weld the core support to the car. use a grinder and lightly remove some of the paint from these areas to better help you identify where the centers of the spot welds are. using a small center punch put an indention in the middle of each one. this also will help keep your spotweld cutter in place. used moderate pressure and a medium speed cut the spot welds out with the cutter, only cuting through the core support metal and not through the metal it is welded to. if you cant get it to release without cutting into the metal behind it use a small metal chisel and hammer and split the welds from the side. dont beat the crap out of it cause you will wanna flatten the metal back out before welding your new core support to it.. now once you have removed the old core support mark the new one in the same locations as the old ones as far as location of cut out spotwelds. drill a hole the same size as spot weld cutter through new core support in same locations you drilled out spot welds. tst for fit and make sure there is the old spot welds behing the holes u put in the new core support.. if the holes dont line up perfect dont worry to much. make sure core support is level with rest of car side to side and is square to the car, not sticking out on one side or the other. you can use welding clamps to hold it in place while making sure everything lines back up... once you know it is where it needs to be mark outer perimeter with a scribe so u can remove it and put it back in same exact location.. use weld through primer or a high zinc primer and prime the bare metal you are going to be welding to.. this prevents future rust problems by galvanizing the welds as you weld them. replace core support and weld the new support through the holes u made in it back onto the car. use a pattern alot like tightening lug nuts. dont just start in one spot and start welding every hole consecutively. you will warp it due to heat and mess the whole thing up. I use a little compressed air to cool each weld a small amount before moving to the next. and i do one weld on left then one on right, so on and so forth. once i have like 6 welds done i start to move the clamps with the welds to make sure each is squeezed together all the way. this helps alot to make sure you dont have a crappy looking job or a repair that is no good. good luck!! any further questions on body work you can ask me directly and i would be more than glad to help!!!

 

[david-b]

Now there's a big paragraph that needs to get broken up. Basically correct though from what I've read. Had to do mine.

Essentially, cut out the spot welds and tack new one in place. Weld. Prime. Paint. Done