I have fitted a bigger radiator and intercooler to my 1200 ute. I measured up to fit a new thermo fan but looks like it wont fit without removing the radiator support. I wanted to know if anyone has done this before and whether it is a good idea?

Put the fan in front of the radiator. There is room up front. That's where I put mine.

datsa73, you only need to cool a 250 hp engine. He might need more cooling.

If you need more airflow for stop-and-go traffic, cutting the core support to allow larger fans is a good idea. Some have even cut the whole front out and boxed the area with square tubing.

The 1200 core support can handle radiator up to approximately 445x695 mm - for example an S14 SR20DET radiator fits no problem.






You can also fit a large radiator and only put a fan on a section of it.

I have had a custom hybrid radiator/intercooler/oil cooler made to fit. It pretty much sits from headlight to headlight. I wanted to bolt the biggest thermo i could to the original radiator support cut out but the lowest profile one i can find is still too high to fit between the radiator and bonnet support. Thats why i wanted to see if anyone has removed it without drama down the track. Ill try upload some pics later to help explain what i mean.

You talking about cutting out the little vertical support under the bonnet latch? If you remove that the top of the radiator support becomes surprisingly very flimsy

Or... are you talking about cutting out the large square projection which essential works as a shroud to the original radiator? A lot of people have cut sections of that out without issue.

If you cut out too much it may be an issue with engineering. I cut enough to get cooler pipes around the front and engineer was ok with it.. but the same engineer has asked others to brace it all with box tube. Just depends on the final appearance and how strong it looks

Are you referring to the Stay? It is only there to support the bonnet catch (lock), i.e. when the bonnet is slammed shut. You can stiffen the rail by using SHS tubing on the rail underside.

Yes! I am referring to the 'stay'. Apologies i was not sure what it was called. If it is only there to support the bonnet latch, im sure the radiator itself would be enough to keep the radiator support straight. The car already is engineered for everything. A little mod will go un noticed ;)

Well then like I said... it does a lot more than you would think... and if your bonnet releases your up for a new bonnet windscreen and panel work on the roof.

On an old car I cut it and bent it a bit lower then added an extension piece in.

Anyway... when you cut it you will see how flimsy the top piece becomes

By the way... radiators are supposed to be soft mounted with rubber insulators which means it shouldn't add any structural strength to the support panel

I ended up massaging the stay outwards a little and grinded of a small piece off the edge where it was still rubbing on the fan. It is tight! but I got it in there without massacaring the front end. :)
Cheers for all the input!