I started opening windows and doors, and re-thinking what I was doing. I did a little research, and talked to a few people, and settled on brazing an aluminum frame for the radiator. The folks over at Pacific Metals in Tualatin were able to set me up with 1" rounded-square 6063 extruded Aluminum tubing at around a $1 a foot. With the angle grinder I got last Fall and a tape measure, I spent Saturday afternoon (between release activities for work) cutting up tubing.
I have a small section I needed at the rear (front-is-front) of the hatch I cut above the engine. I may need more supports around the hole, but the rear edge has no support, so I preped something for that (picture to the left). Then, I cut up the support "U" for the raditator support. The opening "U" will face rearward. Last, I measured, test fit and cut the square-ish frame that the radiator will be bolted to. This will have a hinge at the front so I can determine the best pitch in real testing. I'll support the rear end with cables until I have a firm setting. The picture on the right shows the "U" and the frame as they will be after brazing. All of that tubing consumed about 20' of the tubing I bought.
I'll be breaking out the torch and brazing rods tomorrow night, and I hope to have some pictures of some brazed framework shortly thereafter. By the weekend, I should be ready to cut more for the hatch door supports and a jig to go between the ATV jack and the bottom of the engine. I'll post an explanation of that later.
Sorry I haven't posted in a while. Its been really crazy both at work and at home.