I recently replaced my 92 940 Turbo radiator with an aftermarket. There was no holes on the underside of new one for the screws to attach plastic sprayshield. How important is that shield, can I just leave it off? If not, can I drill/tap into the underside of that new radiator? Thanks to all for the awesome support. John

Any place to zip-tie it on?

-- Kane ... it might just work.
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Blossom II - '91 745Ti/M46 ... Bubbles - '74 144GL/BW35 ... Buttercup - '86 245GL/AW70 ... The Wayback Machine - '64 P220/M40

I had never had to replace a rad yet so I had to take a good look at my rad. I removed one of the screws that held the plastic air baffle in place and found that the radiator had an extra layer of sheet metal on the bottom about 1/2" from the tank for probably protection and primarily strength.

If that extra layer is on the aftermarket rad, by all means drill, but do not tap since the screws are sheet metal screws.

It looks like the sheet metal would grab a spinning drill bit and send it driving into the tank so you may want to use a hand drill. If there is a way to slip in a small piece of sheet metal to protect the tank, that would be better yet. It looks like one slip up with the drill bit and it's goners.
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Tom F

situations like that i have found a rechargable 12 volt drill works well for me... less waft than a mains drill nad genrally they are speed controlled and I find more controll than a hand drill as you can use both hands to controll rather than turning the thing...

I also like the twist-lock type chuck as I find for delecate work (i.e. slow speeds) I can wrap my hand round it and control the 'feed' rate...today i drilled the door panels removing all the material under the covers, but not touching the cover using this method....

of course all of this comes with appropriate disclaimers..i.e. at your own risk!