Quote:
Originally posted by koslov
@ ItsSoLARGE: I was thinking of a shroud, but I can't figure out a design that would work. Normally, you have a fan smaller than the radiator, but in this case it is reversed.
@ jtroutma: Do you know of a place that carries 10" chrome grills?! 
@ jaydee: I thought the res would be a good idea for filling. Also, it would collect any air bubbles. I don't really think airflow through the rad would be inhibited too much, because the res is about 1.5" from the rad. Also, even on the lowest of the three settings, the fan still pushes quite a lot of air. 550 CFM at max, perhaps 200 on low. So optimal airflow is not much of a concern.
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After looking through the pics again I agree about the airflow. But still don't think the res/air trap is needed especially for a space saving project. Theoretically if that rad will always be standing upright like that you could drill a couple 1/2" holes (maybe one on each side) in the top and solder on a pipe to let the air out and to fill. Also that would dramatically reduce any possible brakage/leakage during transport as that res mounting (although I do like it!) doesn't look to strong to take bumps and stuff.