Cooling system FINISHED!!!
 

Cooling system specs:

Howe 26x19 Chevy radiator with custom mounting
Joe's Racing aluminum expansion tank
Pegasus Racing silicone coolant hoses
Dual Spal 10" cooling fans
Moroso 30# radiator cap on radiator
Stant 24# cap on expansion tank

Next stop: Plumbing oil system

Looks like you spent a lot of time on that.

Is that a water sensor right in the middle of the upper radiator hose?

Yeah, that is a custom deal. I'm not entirely happy with it, but it will do for now. The gauge sender is visible, and the sender for the warning lite is on the other side. The top fitting is plugged with a 3/8 NPT pipe plug.

Looks like great work. I'm not crazy about your hose clamps, though... I have an aversion to worm gear clamps.

Itis not ideal to have a water temp sensor after the thermostat... relocate for better accuracy.

This is almost exactly how the cooling system in my Taurus looks, except the expansion tank->upper rad hose is a bit bigger on mine (I've got 1" ID on it ATM, I believe). Are you worried about having the 2 turns in the lower rad hose that it might not flow as easily? I have no clue if that would impede flow, but I was just wondering.

Don't worry about "turns" in the lower pipe. Won't be an issue.

One thing that might be a problem is hose vibration. With those large hose runs unsupported, they may begin to split at the clamps. Worm gear clamps easily cut into the hose and create a weak spot.

There is no thermostat in the system. Just a blank plate to slow the coolant down.

I agree about the clamps. On two of the joints the overlap from hose to pipe is short and the worm clamps aren't doing the job as I'd hoped. I'll be looking for something else.

Fired it up today and found two leaks on the pipe threads, even though I used the teflon tape. After it was fully warmed up, I was able to tighten the fittings a bit further and the leaks are now gone.

The lower hose is under suction, and the hoses I bought were preformed. I don't believe I'll see any issues there.

I hope that you remember that, the whole system is under pressure, the lower hose has slightly less pressure than the upper one (pressure drop in the radiator) but they are both under pressure when the engine is warm.