Well, I ordered a new radiator from Ebay. It's 19 3/4" x 26 1/2" by 1 3/4" all aluminum. Problem is my 'old' radiator was 23" wide, not 26". I bought some hose adapters to attach the intake & output hose. They were 1/4" larger diameter.

I figure on keeping this radiator cause she will give me a little better cooling potential than the old one. Problem is the fan shroud doesn't fit... 3" too short on width. So, I went to Lowe's and bought two 24" x 36" sheets of galvanized steel (from Heater duct work isle). $9.00 each

Before I start the project anybody ever try this before or have any suggestions before I start cutting?? I decided not to go the electric fan route, already spent some money getting this to work.

 

Just a couple of tips:
1. Make a prototype using cardboard or posterboard;
2. The fan should be half-in/half-out of the shroud; and,
3. Account for engine movement so the fan blades don't hit the shroud... about one inch all the way around (= an additional two inches in diameter than the fan).

 

Read an article about this about 30 years ago in a street rod magazine (Rod & Custom I think). Like the previous post mentioned, make a pattern out of cardboard. After everything fits the way you want, spray it with lots of Pam. Lay it up out of fiberglass. When it is done soak it in water to remove the cardboard. Sand the shroud, and add more or paint as needed. They made it sound pretty easy.