4.3L Vortec Engine...Radiator Thoughts & Questions

I have a 1994 4.3L Vortec Engine and will be attempting to position it on the '61 CJ-6 frame within the next week or so. (I just painted the frame and have the engine mounts.) I plan on using this Willys for some moderate 4x4 trails (with 35" or 36" tires) and have it street legal. I have a few questions regarding the radiator.

1) From researching online, I believe a 1966 Musting V8 radiator, 3 core, will work. Is that correct?
2) Aluminum or OEM? It looks like Aluminum is better, but I could be wrong.
3) Do I need to worry about a fan shroud? (I'm planning on using an electric fan.) If so, then can I get that later?
4) Regarding the grill, do you cut the angled piece(?) of the grill to fit, get a later grill, or what?
5) Do you know of a good place to order a radiator that is cheap, but reliable (my funds are quickly running out)?
6) Any other thoughts/suggestions?

Thanks!

 

(1)I haven't worked on a CJ5 but from what I have seen and heard it is very doable. I used a Mustang rad on my Flatty and is working out good so far on the fitment end but I won't have her running for a year or so yet so I can't tell you how well it will work. I don't foresee any problems though.
(2) Either should work fine. Theoretically Copper/Brass has a better coefficient of heat transfer for metal but because an Aluminum radiator can have larger tubes (Aluminum has the strength for it) and better heat transfer to the cooling fins through more surface area, they are more efficient than the traditional copper/brass.
(3) Generally a shroud adds efficiency but in an install like this a 16" fan will cover nearly the whole rad so one wouldn't be necessary in that case. I suggest that if you are on a tight budget, to go to the u-pick wrecking yard and grab an electric fan out of a modern car that looks like it will fit. The Ford Taurus is a favorite of many. Most u-pick yards around here charge $20 for any electric fan in the yard. That is a considerable savings to the aftermarket ones and they usually have higher cfm outputs. I used a 96' Taurus fan but other years have good ones as well with slightly different setups. I can't confirm it but word on the street is they flow 3000 cfm on low and 4000 cfm on high. (they are 2 speed) They are pretty heavy amp draw on startup so use a good relay when wiring it. You can buy control kits from many suppliers such as hayden or flexalite to run them on a thermostat if you like. There are many options on how to wire it, especially with two speeds. You can make the second speed a manual switch for when it is really needed. It will likely cool fine on low only.
(4) I don't have an answer for this one. You will see as it comes together. I think trimming would be likely but easy to do.
(5) I bought my Rad off of ebay from a supplier called Radiators US. They were good to deal with. I bought a single row 1 1/2" tube aluminum rad from them for $160. It is claimed to be able to handle 400HP. They also sell a 2 core 1 1/4" tube core that is said to handle 650HP if you feel like you need it. I am confident a single core will be plenty for me and likely you as well. The 65/66 Mustang rads can have two different inlet and outlet positions depending on 6 cyl or 8 cyl model. Look at where your inlet and outlets are to figure out which one will work better for your engine combo. Some other suppliers for an aluminum rad like this are; speedway motors, summit racing, or even some mustang restoration specialist businesses.
(6) I think I about covered my other thoughts and ideas in the answers to your other questions.

I hope that helps you out some.
Greg

 

Thanks to everyone's responses. More research = hopefully less money.