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You're kind of cascading problems, every time you fix something and then it overheats again and stresses some other component (old rubber hoses, rusty water neck, etc).
A lot of people get away without a shroud for a while if they leave the "A/C condenser fan" in place since that will automatically kick in at a coolant temp of 105C and save the motor. No shroud and no e-fan together is what killed you.
I run a stock shroud on a KA with a 54mm radiator, it does fit, it is extremely tight but it works.
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