OK, here goes....Some advice needed.

1994 RX-7 (early year)
Koyorad Radiator HH060644N

I reviewed the previous advice posted here, taking time to walk through the advice posted by Banzai Racing, very helpful. That said, my production configuration appears different when it comes to the upper right hand AC Radiator bracket. (See Pics). So...there was no way my new radiator was going to "sit down" so that it could be secured by the upper radiator brackets. The upper bracket on the AC Radiator and to a lesser extent, the lower right right bracket. Not an issue for the OEM Radiator because its thinner and sits up higher. Note that my issue is also not so much the attachment bracket that Banzai racing recommends you flip over or remove.

So, the solution appears to me to be to remove some material from the radiator flange, see pictures. Advice needed ....good idea?

I also note that when installed the two radiators are going to be really close, and depending on the welding ridge, touching. My plan there is to apply a thin rubber "rub' strip between the two.


Almost but not quite (Right)

Almost but not quite (Left)

Fully seated left peg

Partially seated right peg

Radiator resting on upper right AC radiator bracket

THE problem

Proposed flange removal area (upper right)

Proposed flange removal area lower right

Not really the problem but may need trimmed

 

It looks more like you fully tightened the upper mounts to the radiator before installing it. Put them on loose so they self center. I've never seen or heard of what you're dealing with. It's a 1% chance you have a bunk radiator. It's more likely your car is not straight or you're doing something wrong than that radiator not meeting QC.

 

Sway bar brackets which are also the radiator supports get bent very easily. I replace them all the time

 

That the radiator still sits low on the right side to the extent the two radiators are almost touching is bugging me. A close examination of the sway bar supports didn’t indicate any damage the first time, but as I measure their placement, something is definitely wrong with the right one. I ordered a new one. It’s going to kill me if that fixes everything.

 

It will. Dead giveaway is if one of your sway bar endlinks is not perpendicular. I usually replace both since they are inexpensive

 

So if Banzai Racing says do something...just do it.

The left AND right sway / radiator support brackets were indeed bent. See pics. Ordered new ones, right hand in hand , left expected in two says. Haven't put the radiator in yet but I

Right side note buckle (Orange pointer) and angle of top of bracket.

Left side. Ditto...

Right side, left was less damaged.
have no doubt it will fit perfectly now. If I had bothered to dig the vinyl undercover out of the parts pile, it would have been a clue (see pic).

So....I can unequivocally say that Koyorad radiators are indeed "drop in" with no modifications required. If yours doesn't fit, your car is probably not straight

 

Glad you have this figured out. Curious if you took any pictures of the clearance of the stock radiator on the top so you can compare with the thicker koyo. I hope you plan to install the plastic cover or replace it with a new one. It plays a pretty big role in cooling.

 

Unfortunately I did not take pictures of the original radiator. I’m sure it was misaligned due to the damage. The new Koyo was just touching the A\C radiator with the bent supports. I’ll take a pic of the clearance with new brackets when I install it. Yes the old undercover is going back on unless I can find a new, or nearly new one.