Managed to get the brackets fabricated and installed and test fitted everything and took it all apart to finish the paint tomorrow.
Yes I had to scrath the window rad--the plumbing was to complicated and would make it a nightmare for the end user to install the motherboard. Everytime the user would want to open the side panel again...nightmare. Looks cool--but was too big an ordeal.
Take a look at what I came up with to mount and seal the rad to the top.
THe PA 160 is easily removed--yet seals the top completely--the aluminum brackets are contoured to follow the molding in the top panel. Once painted they will look like they were meant to be there.
Weatherstrip sals the irregular surfaces of rad and grill together.
I debated about semipermanently adhering them to the top but chose to go with screws.
THe aluminum brackets are made from two pieces of mitered angle--1/2" and 1" in 1/16" thinckness.
I used this special 3M tape that is almost like welding them together.
Here they are ready for sanding, priming, and paint. I am going with candy red to blend them into the case.
Stripped back down...
The top is pretty good..I may just leave it.
The rad needs to be stripped with acetone and primered and painted to match the case.
This piece of acrylic will get a real work out tomorrow on the drill press with a buffing wheel...you won't recognise it when I am done
This troublesome piece is going to get sanded and painted again..maybe three more coats...
So tomorrow will be a prep and paint day and no real progress on assembly until the weekend to give the paint a good cure. Now that I have chosen a course of action the process has smoothed out--trying to engineer the case for the side panel rad was driving me insane
THe other cases all get slightly different treatments--since they do not have a gauge eating ip the space on the ceiling I can mount a 240 GTS up there and see how that performs.