| Been working on/off on this and finally finished pouring the endtanks this evening. Everything came out pretty well and I'll be ready for TIG welding tomorrow to finalize this baby. There's a video at the bottom of casting the piece, with a little of my own commentary. Here's the idea:
By using a double-pass setup, you can put both the inlet and outlet on the same side of the radiator. This will eliminate the need for the lower hose alltogether. One endtank is blocked off at the half-way mark which forces coolant across only the top half of the core. When it reaches the other side, that endtank is open all the way down and the coolant reverses its direction through the core. 
Pt 1: Create endtank patterns 
Part 2: Create molds and cast the pieces. Voila! 
Part 3: Temporarily attach endtanks and test fitment 
This was produced by applying my company stickers to the patterns.
 
Still have a few items to finalize with this such as the bottom mounting studs, shoulders at the top for using the OEM brackets, and a new upper tray to cover the "OEM" look of this core. These will be addressed at my welder's shop and this baby will be going to the powdercoater to have the endtanks gloss-black coated. Here's the video of the aluminum pour - enjoy! (Right click, save as)
[ http://ashspecz.com/Image%20Gallery/2004-Engine%20Build/Videos/HPIM0562.mpg ]
[ ashspecz.com ]
[ agpowers@bellsouth.net ] Enthusiasts soon understand each other. --W. Irving.
Are you an enthusiast? If you are out to describe the truth, leave elegance to the tailor.
Albert Einstein
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AshsZ-II Ultimate Street Z Progress: Double-pass Radiator > - 
07:52:15 01/03/06
