Xj Radiator in a ZJ

[Buzze]

I'm sure there are more people having thoughts like this, me just could not figure out how to find a post about.  
Here is the plan:
We wanna put a nice custom front bumper to my 96 zj 4.0. Looking at it for hours, I always miss liked the extended radiator below the frame reducing the skid plate angle. Also the coolant spots below but that's minor.
Today I escorted a buddy to the junk yard and while nothing else to do I did some measuring figured that the XJ radiator will fit exactly, but in width ;-). Some cutting left and right, the crossbar from the XJ merged with the Hood lock from the ZJ and imported as well. Mechanically it should be possible (with a vision).
Anyhow here are the issues I would like to ask for help:
 
1.) Probably easy,
 The AC fittings at the ac compressor are different. My thought is that there has to be some pressure resistant fitting to connect plain 3/8" and 1/92" aluminum pipes?? Cut the to pipes on a stretch and reconnect them with the popper fitting. Any hints how those connectors are called? Or would that be to easy?

2.) Bigger one,
my ZJ has an Auxiliary cooler connecting to the radiator, but the XJ rad has no inlet for that , ...yet? There is a kind of mark/ nubsy  for an extra hose  prefabricated by the looks. Can this access to the radiator be made? Can the auxiliary line meet the cooling system on a different spot (Hose, Pipe)?

3.) Last but not least,
 is it a stupid idea after all? The vent on the ZJ sits more centred so there is no room for the second electric vent, what is usually added in a XJ. Would you add a custom shroud and lead all air to the one vent,  put a smaller vent to the same shroud, or just assume it is going to be ok because half of the old radiator was solid baked in mud anyways and worked well?

If this doesn't make sense to anyone I may have a very decent XJ Radiator assembly with all hoses and crossbar attached ;-).
The action will lift the lower radiator edge above the "frame", to allow for a hidden winch between rad and a slick one piece Skid plate.
To bad I can't get the radiator pic uploaded to show what pipies and marks tf I'm talking about, but I'm sure you can guess ;-).
Thanks,

[cLAY]

The rad in my xj barely kept the 4.0l cool. With the extra weight of a ZJ I'm guessing its going to be an issue. Got a V8 in your ZJ? If so then I wouldn't even bother.

[JackstandJohnny]

the XJ rad will probably not fit, seeing as on ZJs the air box and battery sit at the front and i don't think they do on an XJ.
have you measured both rads yet?
also, you'll need to run some sort of dual electric fan setup as your mechanical one won't really line up. 
yu'll also need to run an external tranny cooler cause you don't have one in the rad anymore.
start measuring and go from there

[cLAY]

They are at the front on an XJ but opposite sides. In fact an XJ battery tray is easily adapted to a ZJ for a second battery.

An auto XJ rad should have ports for a cooler, I'm guessing his came from a manual tranny model.

XJ uses two fans, a mechanical one offset to one side and an auxiliary electric one next to it. ZJ fan is centred but bigger so probably not an issue.

Still think it will be too small to adequately cool. However if you do get it to fit you could then confidently have a custom one made with greater capacity. But then you may as well just go with a custom one to start with.

[Buzze]

It's a 4.0l. So the tranny oil runs through the Auxiliary cooler in the front and the main radiator.  
Would two more auxiliary rads be able to cool the tranny enough?

The battery  will interfere with the radiator inlet hose. I think if we turn the Battery 90deg it should be cleared (probably just because the battery they gave me last time is to small for the original Holder).

The air filter would be in the way for the secondary fan. The air filter nozzle definitely has to go while it sits beside the Lights and there need to be room cut for the rad itself. This issue has to get modified anyhow because I'm tired of installing a new filter pad after attempting some paddles to fast.

Custom Radiator is unfortunately not what I can consider to be in my Budget ;-).
If we get the AC lines connected and run the oil through two more aux coolers it may work even with pipe sizes.?
One or two 8" fans could find room in front of the rad.
On the end the XJ rad may have even more surface while most of the ZJ cooler is covered behind bumpertin, dirty, or used for oil?
If I look for a automatic rad I should have an oil cooler in it?

This little aux rad in a ZJ is 5"X10", with out any background on this I could think two or three of them in a loop will keep some tranny cool you think?

[Buzze]

Ey. and thanks cLay for the vacuum hint on the other Post ;-), go figure why my oil pressure went down while temperature seemed to be pretty low. There is a dent in the bottle since before I got her years ago. Hope I did not run her too hot, for too long. Lets do that right ;-)

[JackstandJohnny]

Sounds like you have talked yourself into doing this project. So..... Do it and post pics!!!!

[Buzze]

HaHa yeah well, I don't know. I tend to talk myself into some stuff, lol. But me and my friends get tired of that someone else needs to get me out on the end, lol.
But as longer I think about it, without "ground control", as more I like the idea.
I'm not a mechanic so I can judge only based on common sense and spirit of adventure. So, my best bet on experienced opinion to what I fantasize is you guys.
Thank' s, if I will go for it I will revisit how to upload pic's. ;-)