Thanks Charlie, yea it never seems to end.

We hit it pretty hard today. Mel started setting up the battery brackets to get them welded and I started figuring out how to cut the holes in the aluminum panels for the radiator shrouds.
Here are the brackets as Mel was figuring out how to clamp this mess together for welding.
http://images58.fotki.com/v696/photo...MVC003F-vi.jpg
He made some small angle iron brackets to get everything clamped up. Once it was clamped up we tacked all of the pieces together so we could mock it up in the van.
Here are the tacked brackets set in place on the fender mounted straps.
http://images108.fotki.com/v1623/pho...MVC020F-vi.jpg
http://images55.fotki.com/v585/photo...MVC021F-vi.jpg
Once we got everything squared up I tacked the brackets to the fender straps.
http://images58.fotki.com/v132/photo...MVC005F-vi.jpg
It's amazing how strong these little guys are! They shouldn't have a problem holding up a battery.
http://images51.fotki.com/v1586/phot...MVC007F-vi.jpg
While Mel was building stuff to build stuff, I was building a top for my router table. I used a piece of 1/4" plywood and clamped it to the top of the table. I used this to spin the aluminum panels around a center hole to cut out the fan openings.
http://images55.fotki.com/v605/photo...MVC009F-vi.jpg
I used some Castrol stick wax to lube the 1/4" carbide cutter in the router.
http://images108.fotki.com/v613/phot...MVC010F-vi.jpg
In order to "keep" the center of the hole from falling out, I had to stop short on 3 of the cuts. You can se the end of the first cut at the top of this pic. The bit is set in the next hole and the stick wax is spread on the cut line.
http://images49.fotki.com/v1511/phot...MVC016F-vi.jpg
I drilled 1/4" starter holes at 4 points and ran the router up till it was a 1/2" or so shy of the next hole.
This was pretty noisey but it worked well and I got both openings in the radiator shroud cut along with the one for the trans cooler.
http://images15.fotki.com/v792/photo...MVC003F-vi.jpg
Once I got the holes cut I worked on the trans cooler shroud. I laid out the shape and bend lines and did some off hand cutting on the verticle band saw.
http://images59.fotki.com/v426/photo...MVC008F-vi.jpg
http://images16.fotki.com/v220/photo...MVC009F-vi.jpg
I bent the .090 aluminum in the 3 in 1 tool. It was kinda tuff but it did the job.
http://images20.fotki.com/v422/photo...MVC011F-vi.jpg
All bent up and sitting nice and flat... I like it when it comes together like planned...
http://images108.fotki.com/v1623/pho...MVC013F-vi.jpg
I had to set the mating components in place just to test the fit. Perfect!
http://images15.fotki.com/v1626/phot...MVC017F-vi.jpg
http://images108.fotki.com/v1623/pho...MVC018F-vi.jpg
http://images109.fotki.com/v144/phot...MVC020F-vi.jpg
I'll try to get out in the shop after work this week to get the rest of the trans cooler shroud pieces made. They are pretty simple and shoud go quick.
Thanks for looking!
Mark