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Yes you can get away with not cutting the grill. If you are gonna play in mud all the time then your radiator will clog without a front mount anyway. It's just a matter of maintenance. The only time...
Personally I'd go top mount air to air as it's the cheaper option to go with and many ready made kits to purchase.
Water to air is the best cooling but expensive or more maintenance
Air to air is...
To be honest mate you haven't really given us much to go on so we are all struggling to give you any sort if advice. You need to give us as much info as possible otherwise we cannot help.
If yours is already a silver top then just rebuild with the same gear. If you have to replace the head the why not replace with a turbo head. Get it all balanced as well mate it's cheap enough and...