1977 F150 4X4 lifted with swapped in 460. Radiator is old and want to replace it. I don't know what size to get 2,3,4 core? Also, is Aluminum they way to go?
I also see New Raditor at champion with electric fans and relay kit for upgrade. Can I upgrade to this electric system without upgrading alternator?

 

Instead of replacing it, why don't you get it recored? The old rads can last forever if you want them to - certainly will last longer than their new aluminum counterparts.

Read up on aluminum rads before you buy. 2 core rads can sometimes have more cooling surface area than 4 core aluminum rads. More surface area = more cooling. I went with aluminum because my local shop wanted $400 CAD to recore my rad... I've heard of others on the forum getting a rad recored for MUCH cheaper than that, and they work like new.

Yes you'll have to upgrade your alternator if you want electric fans - electric fans require a HUGE surge of electricity when the high speed is turned on. Your old alt likely won't be able to handle it.

A new 3G alternator is very easy to install and there's a great thread on it here - Just did a 3G upgrade.

I wouldn't go with a champion electric fan system... You can find plenty of electric fans at the junk yard that are just as good or better than whatever junk champion is selling.

 

Where I live there are no Radiator shops anymore, not any at a decent distance

 

 

I'm running a champion 4 row, with plain ole clutch fan with a 400. It's been a great radiator. They're not that expensive, so I wouldn't even consider having repair work done on an old radiator.

 

Me too. The Champion 3 core is a good all around radiator and the 4 core has more capacity + wants a strong fan for cooling at a standstill.

I painted my Champion black and used a stock shroud.

The mechanical fan setup can be very effective and will not tax the electrical system.

If you want electric, use an OE style fan. Lots of posts on options. The (tiny) dual fan setups sold by Champion and others do not move enough air to cool at a standstill and block airflow at speed. Worst of both worlds.

 

Go with the aluminum champion radiator. Super cheap and very good quality. Do not use their electric fans! Stay with a clutch fan and shroud if you want the best cooking. No radiator shops within 200 miles of me re-core radiators anymore.