KX Guru Racing

Very nice!
What you have done to make these fit is what we have been doing for some time, including the gussets.
I've been so busy I have not had time to post the updates but you essentially covered the details.
I appreciate you covering it.
It's too bad that they didn't come this way from the manufacture as it would sure make things easier

Finally got this bike together, done about 7 heat cycles and no leaks so far.

7 heat cycles?
She is ready for some action..

7's for good luck

It's a Kawi.. No luck needed

Update on the rads, I saw a little wet spot under the front end of the bike, turned out to be coolant. I'd guess the bike has about 30 hours on it. Left side radiator was leaking from underneath the mounting tab that is welded onto the bottom tank of the rad. Not sure what made it start leaking - I didn't bother to grind it off to look - I'm guessing the vibes caused it to crack on one of the welds. Had to cut off my brace to weld all around the base of the tab and then weld it back on after.

Might be worth welding all around the bottom tab on both rads while a guy is welding on the braces when you're first installing the radiators and you got the welder out.
I thought about pulling the right side rad and preventatively welding it up too, but then I'd never know if it did crack and leak. If it does start leaking I'll know that is a weak point on these rads and the left side wasn't just a rare case.

It is sad but your experience is very common.
I have some of those rads on a KX500 that is only used on the street for testing our land speed engine runs.
The mounts have already cracked and broke in 3 months of usage.
It must be the quality metal called Chineseium...