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My customers would laugh in my face if I told them that a 20 degree difference is good! lmao Especially when its 110 outside! I'm sorry but if the air blowing out of the dash vents is 90 degrees something is wrong!

I had to make the same modifications as you for my champion rad. It works really well here in the desert. My 440 stays at 185 to 190 cruising around here when its 105+ outside. Cruising down the highway at 3300 rpm it runs at 205. Very nice radiator and for the price you cant touch it.

I would get the radiator boiled out and flow tested, I dont think its flowing very well.

No other symptoms at all, just the darn thing would quit on its own. That was our last shot at repairing the car or else we were sending it to the dealer. Low and behold it fixed it. See if you can find a used control unit at a pick and pull, should be pretty cheap.

I have seen this same issue on a stratus last year, a/c would just go away when it warmed up. It was very hard to diagnose. We had replaced the pressure switches with no luck. We ended up replacing the hvac control unit and it worked perfectly. Not saying thats what your issue is but it very...

For sure. The be cool dual fan setup on my swinger has that exact thing. You could make a few large cut outs in your shroud on the passenger side and attach some sort of rubber sheet to flap out while driving and close when stopped.

Vent holes would help tremendously for the highway issue, but it would effect the fans performance when idling or stop and go driving. I think the bigger hhr fan would work nicely.

just judging by the picture of your current fan set up, it looks like atleast a third of the radiator is not being used. As in the shroud covers up a great deal of the surface area of the radiator. If the car doesn't cool while driving down the highway it leads me to believe either the radiator...