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Please Help fix this lower rad support

Discussion in 'Gen 2 Prius Main Forum' started by T.S. Elliot, Jul 22, 2021.

  1. T.S. Elliot

    T.S. Elliot Junior Member

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    Hello all, hit a racoon going fast... again. Destroyed rad, condenser, fans and shroud, tweaked upper rad support, and nearly destroyed lower rad support. I have new Denso cond. and rad ready to go and a rough '05 parts Prius for ancillaries. Unfortunately, the damage to the lower rad support was worse than I hoped. As you can see in the pictures I was able to bend it back some but it will never be the same. I have mulled my options and have come up with several ideas.

    #1 run as is after some final body work (i.e. more sledgehammer) drawbacks: it's already going to be tough installing the new rad as is, not sure if even possible as the clearances are even tighter now with everything tweaked slightly inward.

    #2: Cut out the middle section of the support in between each of the rad support holes, and then run treated wood in between what remains to bridge the gap. Once disconnected in the middle, I may be able to be able to bend them back so the rad support holes are closer to where they originally lie.

    #3: Cut out an even bigger section (including the rad support holes) and then cut out the entire lower rad support from the parts prius and lay it on top of the ends. If they stacked onto each other nicely this would in theory be the best option. However, given the state of my lower rad support, I predict the new one wouldn't lay together nicely with it.

    Drawbacks to cutting options: I don't currently own or know how to use a plasma cutter. The other problem is being totally committed once you start - no turning back. Also a chance of damaging already bent ac lines, and other items. Please if anyone has any ideas thanks

    btw not fixing is not an option
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    #1 T.S. Elliot, Jul 22, 2021
  2. M in KC

    M in KC Active Member

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    T.S. that whole lower rad support and its orientation is pretty critical. there is a lot going on in a very small area in all three axis'. There isn't a lot of space to have things misaligned or out of orientation. You are probably best off to cut out your damaged component and replace with a new or a new to you one from a junk yard. .02
     
    #2 M in KC, Jul 23, 2021
    T.S. Elliot likes this.
  3. T.S. Elliot

    T.S. Elliot Junior Member

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    It looks like the lower radiator support is "stamped" into the frame somehow. I wonder if it would be possible to drill these stamps out and rivet it back into place??

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    #3 T.S. Elliot, Jul 23, 2021
  4. ChapmanF

    ChapmanF Senior Member

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    I believe you are looking at spot welds.

    If you look in the collision repair manual (more info), it will show you the exact locations needing to be drilled and/or cut and how, and the right means for fastening the replacement part (with details such as whether each weld is to be drilled 'outside', 'middle', or 'inside').

    For example, my 2001 collision repair manual (which is no use for your 2007, other than as an example of the kind of information) shows seven outside spot welds and three inside ones, at each end of the lower support.
     
    #4 ChapmanF, Jul 23, 2021
  5. mr_guy_mann

    mr_guy_mann Senior Member

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    Those are "spot welds". They do make special drills (or rotary cutters) that will cut through those. However the best way to put back together is welding. Maybe you can find a local guy with a mobile rig who would come to you to do a small job like that? You can buy a small wire feed welder for a couple hundred (or a MIG setup for maybe 500) but it takes a decent bit of practice to weld sheet metal without blowing through it.
    It looks like a boxed cross section so I'm not sure you can get bolts and nuts tight enough without crushing things. Rivets could work- but I would only consider 1/4" steel rivets, which need a fairly serious rivet tool to set them (and access to fit the tool where you need it).

    Posted via the PriusChat mobile app.
     
    #5 mr_guy_mann, Jul 23, 2021
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