Insulating the radiator shroud to prevent debris build up.

The purpose of this modification is to prevent the future build up of debris (leaves, wrappers, bugs, etc) that our cars pick up. C-4's are bottom breathers and act like vacuum cleaners. Because of the gaps in the radiator shroud, specifically around the AC condensor, this stuff gets sucked in and trapped between the radiator and AC condensor. This blockage can cause overheating. As an added benefit to this modification, your cooling system will run more efficiently, as more air is forced through the condensor and radiator, and not around it.

Before proceeding, we are assuming here that you've got a shop, Haynes, or Chilton manual which you can refer to for removing the radiator. The AC condensor can remain in place, but you ought to remove any line brackets so that you can move it around.

I used AC insulating foam weatherstrip which you can purchase at any hardware store. I bought MD brand and I am currently contacting the manufacturer as to it's suitability for this application. It measures at 1-1/4" square and 42" long. I purchased four packages for under $7 and it only took 3 to insulate the entire condensor. Not too much of an investment, so we'll see how it stands up. I considered using non-expanding foam sealant, which is still an option. You do not want to use expanding polyurethane foam. Here is a picture of the package:

i cut the bottom strip 24" long and the top strip 23.5" long. The bottom strip is held in place by the weight of the AC condensor, while I used weatherstrip adhesive to glue the top strip to the upper radiator shroud. Here is the underneath (upside down view)of the top radiator shroud. The top of the picture towards the front of the car. I used additional weatherstrip adhesive to glue the foam to the rubber grommets used to keep the radiator and AC condensor in place.

Here is the view of the top strip with the upper shroud on, looking from the front of the car. If you're wondering what that other thing with the blue cap is, it's a tranny cooler I'm installing.

Here is the front view of the bottom strip. It butts up against the front of the shroud.

The left over pieces from the top and bottom are just the right size to use on the left and right of the AC condensor. I used the third package to double up the sides. I cut two strips of cardboard the same width and lenght of the foam pieces. I used these pieces to sandwich the foam inbetween them. You can then use the carboard to act as a shoe horn to position the foam in place. When the foam is in place, just slide the cardboard pieces out, don't pull them straight up, but pull the top side out first, followed by the bottom. Here is the driver side view. It looks messy, but you have to position it while you put the shroud on.

Here's the girlfriend side view: