Because I don't have enough going on in my life I have decided to save some money and start fabricating my own RAD relocation brace and tubing. The goal was to use the existing mounting brackets, make it solid and keep it light weight. There are only 4 connections to the rad the bottom coolant hose, upper coolant hose, electrical connection for fan, and coolant overflow line. There isn't enough hose or electrical lines to run up on top of the box so we'll be extending all the lines. I will be mounting it directly to the front storage box and plan on not using the front box for storage.

I do plan on snorkeling in the near future and if you plan on doing the rad relocation it's a good time to check your diff vent lines if you have them. On the 09 X2 500 there are 2 of them, 1 on the front diff and 1 on the rear. Each line runs to the pod and don't need to be extended.

Here are some progress pic and I'll continue to update based on the progress.

Pulled the rad, drained, and cleaned.

 

We were able to use all the stock brackets and we used 1/4" steel for the brace. There are 2 separate braces inside the box equal length to those on the top. We did this for stability because you don't have much to grab onto on the inside of the box. Next is mesh the front for protection and hoses/wires.

 

As of last night this is where we are at. Main frame done holding the rad. Aluminum plating for protection along with mesh front. All hoses are ran.

 

Pretty much everything is done outside of the electrical to the fan and putting the plastics back on.

 

Looks good! It's really not a bad idea on these machines. They put them so low they get clogged pretty easily.

 

Thanks Moose. When we took the rad off we were like, huh, that looks pretty clean. Until we took a power washer to it. It took about 5 minutes to get all the crap out of it. I would agree, they do sit low on this machine.

 

I had a slight overheating problem that was happening even when it was 16 degrees out. Radiator got pulled out and there was clay hardened up in spots I couldn't possibly get to leaving it in place.

 

Final product







Fan Override



4x4 Reverse Override

 

Very nice. Looks great!

 

Great job!!!!