Finally some progress worth posting...
I was able to finish up most of the upper and lower radiator mounts. Since the grille is hard mounted to the frame I attached the lower radiator mounts to the new crossmember I added under the grille. That crossmember also houses the power steering cooler so the radiator mounts needed to bolt on. I decided to do a channel in channel type mount.
The lower mounts use 3 mounting bolts to provide some sideways stability in the long term. There is a secondary mounting nut in the mount for an air flow plate to help force air through the coolers and keep re-circulation down.
The upper mount attaches to the front top edge of the grille and uses the same Jeep XJ mounting pads as the bottom. This makes for easy to find common parts. The radiator is slightly offset to the passenger side so the mount isn't perfectly symmetric. I tried to hide that in the visible parts when the hood is closed. The dimples really stiffened up the panel overall. I am always amazed by that.
One interesting thing with the FJ40 front clip....
There is an opening for airflow on the front of the hood above the grille. I added a few holes on the front to the upper radiator mount. I omitted the outer most holes ( I can add them ) because I am thinking about adding a small 'scoop' to the upper radiator mount. That scoop would capture air from the hood opening and force it though the upper part of the radiator....and keep the fan from sucking hot air from in the engine compartment. Thoughts?
Misc stuff....
new style of weld nuts. I like them. Cheaper. Easier to weld into place. More threads.
Lower radiator mounts out of the chassis.
I have some some more air flow 'ducting' to do in the grille still. I need to make a shroud. I can start on the front bumper now. Need to mount the headlight adjusters and figure out the final depth for those. The hydro assist ram also needs mounting before the winch. I'd also like to start working on the bed....
