When do you need to upgrade cooling system?

Maybe. Youll have to sit in traffic to find out. If the temp rises while sitting or cruising and the cooling system cant keep it cool then you need to upgrade.

FWIW I have an aluminum radiator im looking to sell if your interested. PM me if interested.
 
As long as your stock components are in fine working order, there shouldn't be any issues. Obviously, they will be streesed with more heat to reject but they will work if money is short.

You can also look into a Brass 3-core radiator that is less expensive as aluminum and cools just as well (I'm putting one in my Mustang this winter.) An electric fan / DSS controller might also be a good idea if your electrical system is up to the challenge. (I just won a Mark VIII fan on ebay for $25.00)
 
You can get 3 core replacement rads cheap these days,and add a High-Flow thermostat.Part stores should have high flow thermostats,I believe mine is made by Moto-Rad.
 
A brass/lead 3-row recore on your stock radiator should cost about $150 and handle this car with ease, although you should expect to see these traditional types of radiators, and the shops that upgrade them with bigger cores, disappear in the near future as plastic and aluminum radiators become universal. On a basic hi-po upgrade don't go with a "high efficiency" core, since these add extra fins that can actually restrict airflow through the radiator, which will hurt when idling in traffic. Ditch the stock 192 and use a 180 degree thermostat, but don't go down to a 160. Those will run too cold and cause a rough idle and rich condition. And take my word on this: if you have or suspect a problem with the stock fan clutch, spend the extra money it costs and buy an actual Ford replacement fan clutch. It costs about twice as much but every other aftermarket fan clutch I have ever encountered on a Ford has been too tight, which costs HP that you can really feel in your butt. I'm not kiddin on this -- spend the $100 plus bucks it costs and not the $50 you can spend at the Pep Boys. This is a serious difference and after a 289, four 5.0's and a 351W, I have found that there is no aftermarket fan clutch that both cools properly, and correctly freewheels to give maximum HP, like a real Ford unit. Just telling you.
 
yup same here, i have h/c/i combo and still have the bone stock radiator, fan and shroud and everything and with a 195 stat it goes no higher than 200degrees. I used to have a nice thicker radiator but got a leak in it so i through a stocker in it. Im saving up for a 130 amp alt. conversion so i can get a electric fan cuz my mechanical fan is LOCKED up.