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he wouldnt make it work in the shop he is just helpin out a fellow ford guy with a question on IF it will work. If it was me yes i would go with the newer cooler but if the guy can save 4-500 bucks by tacking it on there which is just as strong as a small bolt holding it in there then by all means go for it!! whats the worst that can happen the weld breaks. just get back in there and make it stronger or make a support bracket for it.
I would talk to bullet proof diesel and see if they will work a deal with you to swap coolers. I have dealt with them many times before and they are easy to deal with see what they will do. I would just not like to recommend to some one to weld on a 500 cooler.
3 choices...
leave the bolt out. may or may not cause a y-pipe issue.
move or add a mounting tab to the cooler. find someone with a tig welder and pay $50
add a mounding tab to the intake for it once again mig it or tig it.
when ever we opt to change things from any type of stock form there is always some give and take. be it more money or modifing things to work.
and yes you are correct the do have the mount tab about an 1" apart. but none the less it will work
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