Assembling the Radiator was fun, a little challenging and a satisfying day's work spread over three days. It is important to really understand how the Radiator Core and the Cowl go together, which way is up and what are the interferences before proceeding as the manual has some minor errors in it that will just add to your confusion. Unlike as shown in the manual my Cowl did not come with the holes pre-drilled for the inlet and outlet hose nozzles. As shown in the top photo I managed to screw up my measurements, probably because I had not cut off the four mounting tangs on the top (same side as the nozzles) side of the Radiator first. Cutting them off lets the Radiator sit tighter to the Cowl, which is especially important in getting the aft end of the Radiator to fit into the Cowl and the mounting bolts to be placed correctly. As detailed in the manual you also have to drill & tap the bottom side Co-pilot side mounting tang for a 1/4' Allen Bolt. The manual says 'Pilot" but their photo shows the Co-pilot side. I don't think it makes any difference as this is just a test port I believe. I had to drill a 3/4" hole in the Pan to allow the Allen Bolt and Tang to protrude through. The Radiator bolts into the Cowl at four locations. The manual calls for AN4-12A bolts but I used AN4-13A bolts because I had no 12's and the 13's were barely long enough anyway. The four brackets mount to the pre-drilled holes in the Root Tube. The manual calls for AN4-23A bolts which I found to be not long enough, so I used AN4-25A. The pre-formed Hoses are a bit of a mystery as their shape and length must have been fashioned for a 747 not a Searey. After calling the factory I learned you basically just cut and twist a little to suit. This worked for me except that the Radiator end of the pilot side hose was not expanded to fit the 1" nozzle so I have asked for a replacement.
