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You are dead on on all accounts. I dont know how the brackets from dewitts are made. I made mine to be a snug fit, but not too tight. The outer and middle ridges of the fans do touch the core. I split some vacum hose down the middle, and put it over the parts that touch, just so it would be cushioned a bit. I didnt do that with the orignal rad which fit the same and never had an issue, but decided better safe than sorry this time.
It is a tight fit to get it all in there and the ABS is in the way. No big deal there though. Just take out the too bolts that hold it to the crossmember at the bottom and it moves enough to get the fans in. Once they are in it goes back no problem. The abs is only in the way getting them in, not once they are in place.
It seems that every job never goes as smooth as I think they will, but they turn out fine in the end.
Thanks for the feedback. Now I know I can clear the ABS. I'm also going to put the rubber hose on the edges of the fan. I'll see if some thin stick on rubber will fit between the brackets and the tanks. Now I just have to get my lazy *** under the car. I'm really not looking forward to pulling the radiator. Last time I could not get the condensor
off and out of the way and ended up having to open, vac and re-charge the A/C.It just would not slide up far enough in the hooks to come out due to the lines hitting. I will try hard to avoid that this time.
I'd like to turn my cooler horizontally like you mounted yours too.Mine is vertical and uses every millimeter of available space.
When I'm done I want to make some grills for the fog light openings. I've not found any suitable material yet.