MOUNTING (2)  Focus Radiator (1) Hoses (3)

Here we have the mount selection I scavenged at Spalding's.  (Local wrecking yard)  In the end, I used the two small donuts as spacers for the Galant top mounts, and modified the original Focus lower mounts.

It must be the former maintenance mechanic in me, but doorstops are used for the lower mounts.  Why?  I was going to have pieces of pipe welded to the core support so the bottom edge of the bottom mount (where my thumb is) would seat inside it nicely.  But as I don't have a welder right now, that wouldn't work, and I couldn't get the car over to Joe's shop for him to do it since the radiator was out.

So I went up to Lowe's and found a doorstop that conveniently was the exact dimension as the widest part of the bottom Focus mount shown.  Now what?

Yep!  Nothing like alternate engineering.  Cut off the bottom portion of the mount, cut off the doorstop rubber bumper, flip upside down, and mount to core support with the metal screws bought with the doorstops.  

(EDIT: 8-19-08.  DON'T use metal screws as shown in the picture.  Use larger common metal 10mm head screws from later model Japanese cars.  About 8mm by 3/4 inch sheet metal black anodized screws like the kind that hold various dash parts together.  The screws shown broke off at some point and were just sitting there when I removed the radiator for the race motor install.)

You'll also need to Note, as mentioned above, you will need to trim the radiator post since you just cut off a half inch of material off the bushing.

Pop the radiator in, mark your spots.  It's pretty hard to screw up because with this mounting system, you only have about 1/8" on either side of the frame rails.  Run the metal screw in before you put the mount down.  Don't screw them down too tight, note the number 3 screwdriver in picture.  Again, make sure you have trimmed the bottom radiator post.

***IMPORTANT*** There's not that much lip on the doorstop.  What I suggest is use blue silicone or whatever other RTV you have in the shop, and after checking fitment, take off the lower stock Focus mount, and silicone it to the back side of the doorstop.  It has the hole for the radiator post, so you'll be able to take the mount off in future, but it will ensure the radiator can't pop out while say rolling over at 60 mph.  Not that it matters at that point anyway...

Next, test fit the radiator and figure out the top mounts.

For this I decided to use Mitsubishi Galant top mounts, but probably any similar style will work.  They weren't quite perfect; the holes needed enlarging, so with an exacto knife, I cut about 1/16" around the edge.  Rather a pain, even with a sharp exacto.  In the end they fit pretty tightly, but not too tightly.

These rubber spacers were lower mounts off a random radiator in the scrap bin at Spalding, but pretty much just use any rubber type space that will work as there will be a slight gap between the top mounts of your choice and the straps you use.  A section of rubber hose would also work fine.  Had these not fit, that's what I was going to do.

Hot dog, it's mounted!  Now to hook up the hoses.  Also note the top post of the radiator is uncut in the above picture.  You will need to trim it down to clear the hood crossmember.  Fits like a glove.

MOUNTING (2)  Focus Radiator (1) Hoses (3)