The Goal
This project started with a simple problem: fitting a full-size radiator into a K20/24 Frankenstein EK Civic.
With the engine conversion, packaging requirements, and intended use of the car, the standard radiator setup was no longer ideal. The aim was to create a clean, strong mounting solution that positioned the radiator properly and allows for isolation from vibration.
Starting With a 3D Scan
The first step was to 3D scan the front of the car.
This allowed the radiator area, front panel, chassis structure, mounting points, and available space to be brought into CAD. On a swapped EK Civic, space can disappear quickly, especially once you start packaging a larger radiator, pipework, oil cooler, intake routing, and other supporting parts.
The scan gave a clear reference for where the radiator could sit, where the brackets needed to mount, and what clearances had to be maintained.
This meant the parts could be designed around the actual car rather than relying on rough measurements or trial and error.
Designing the Radiator Mounts
Once the scan was brought into CAD, the upper and lower radiator brackets were designed to suit the available space.
The lower brackets were designed to support the radiator securely from underneath, while the upper brackets locate it and prevent unwanted movement. The aim was to keep the design simple, strong, and easy to install, while still looking like a proper finished part rather than an afterthought.
The mounts were designed to work with custom isolators, allowing the radiator to be held securely without being hard-mounted directly to the chassis.
Custom 3D-Printed Isolators
To help isolate the radiator from vibration, custom 3D-printed isolators were designed for the mounting points.
This allows the radiator to sit securely in the brackets while still having a degree of compliance. For a part like a radiator, this matters. Hard-mounting can introduce unnecessary stress into the end tanks, cores, and mounting points, especially on a car that will see hard road or track use.
The isolators also helped make the final mounting solution neater and more controlled, rather than relying on generic rubber parts that did not fit the application properly.
Oil Cooler Bracket
Alongside the radiator mounts, an oil cooler bracket was also designed as part of the front-end package.
As with the radiator brackets, the oil cooler mount had to work around the space available on the car. It needed to position the cooler properly for airflow, while keeping it secure and serviceable.
Final Manufacture
Once the designs were finalised, the brackets were laser cut and bent from aluminium.
Aluminium kept the parts lightweight, corrosion-resistant, and suitable for the environment they would be used in. After fabrication, the brackets were powder coated black for durability and a clean OEM-style finish.
The end result is a set of custom radiator and oil cooler mounts that fit the car properly, support the cooling package securely, and look like they belong in the engine bay.
Why This Matters
Small fabrication jobs like this are easy to underestimate.
A radiator bracket is not the most glamorous part of a build, but it affects reliability, packaging, serviceability, and the overall quality of the car. Poorly mounted cooling components can crack, rub, vibrate loose, or make the front end difficult to work on.
By scanning the car, designing the parts properly, and manufacturing them as finished components, the final solution is cleaner, stronger, and easier to repeat.
This is the kind of work 7 Works Engineering is being built around - practical engineering solutions for modified cars.