A TIG welder is on my list, but since I can get it done in 2 different shops locally, it may not happen. I might have $200.00 in total welding cost on this project, so I'm kinda far down that road already. Will there be another project? .......it's not on my list at the present time.
Working with metal, and 304 stainless especially, is not forgiving. If you put rotary sanding or grinding marks on a brushed surface, you'll spend a whole lot of time getting them out. It's not at like wood where you can sand a little harder or deeper and you're good. Some of the grill bars were recessed a touch and even that calls attention to them if you look closely, but perfection is not the goal or I would never finish.
I really like the "improved" version with more grill blades and I'm hoping I still get enough air movement through the radiator. The aluminum radiator, electric water pump, and dual fans are an improvement over stock, but the 350 Chevy motors always ran a bit cool anyway, so I think I'm good with that. I don't know how you would calculate grill area vs airflow anyway, so I just "winged it". Trial by fire or trial and error at least I hope not!
When you change so many parts of a system, rebuilt motor, rebuilt trans, different cooling components, hydro boost brakes, 200 AMP alternator, etc. you just have to do your best research an hope for the best. The whole wiring of the instrument panel is over my head as far as the digital instrument cluster although it's a simple wiring diagram. I have redundant oil pressure and water temperature and tach so I can run the engine without fear until the "wiring expert" has time to take over. I also bypassed the steering column stat/ignition switch, so the one in the column is just for locking the steering wheel. There a big honkin' connector at the base of the column which is over my head, but I need turn the signals and wipers to work ultimately , so I'm counting on Randy the wiring guy.