I first thought of filing down the shroud but I thought the area was already thin and i didn't want to weaken the shroud. I would have had to remove over 1/4".

A friend had a similar problem but not as severe so he put 3 washers between the top of the shroud and radiator yoke. I didn't like the small contact area being so so I didn't go that route.

The heat gun and bending the shroud back to original seemed to be the strongest option. Yes it is more work but driving on gravel roads I need the strongest fix I can reasonably perform.

BTW, when I bought my Aveo, the dealer had 20 Aveos on the lot and this is the first they heard about the shroud warping or damaging the radiator. Yea, sure, I have a bridge I want to sell.

2008 Aveo, 5 door, 5 speed, no A/C
39MPG @65MPH, 4 studded snow tires on 1984 Dodge Caravan 4 Cyl-4 lug rims same specs including +- 2mm offset.

I take out the passenger and back seats, install my bed size 1/2" plywood board, sleeping pad, sleeping bag, and sleep in my car in a remote camping site that is 60 miles off a rural Hwy.

I also carry (seats removed) 16 ft long lumber and 600lbs of ready mix cement in my Aveo. Best car I ever owned and the car snobs give Aveo low marks. Their loss.

I see they are made in a car-pickup version for the southern part of Africa. I guess I missed out on what I truly needed.