Need help QUICK, can this radiator CORE be fixed???

[tsi1991awd]

I was drilling out some spot welds and drilled too far on one of them and the drill bit punched part of the radiator core. Do I have to buy an entire new radiator or is there something I can do to fix this???? Any ideas? This is practically a brand new aluminum radiator.

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[Dhan]

It's kind of hard to see in the picture.

You could probably straighten out the fins with some pliers. I damaged the radiator on my Mazda similarly to what yours looks like in the picture, but was able to salvage it.

However if you've punctured the core, it would probably just be best to get a whole new unit.

 

[BIRDCLAWTSi]

That sucks dude. Is it leaking coolant? If not, Not a big deal. If it is, I dont think you can fix it. From the pic, It looks cosmetic.

 

[sledge42hammer]

If you have steady hands and a few tools you can fix. If you look close the core itself is torn. What I've done with radiators and oil coolers is eliminate that passage. one passage will not make a difference. Use a die gringer with cut off wheel and carefully cut through fins on both sides of damaged area. There is then three options to complete:
1: **BEST** pinch closed as tight as possible and solder shut (solder should have some tin in for strength).
2: carefully use needle nose pliers and fold over itself (copper only)
3: fill with jb weld and pinch some to get full seal

Good luck!




JAREDJ

 

[tsi1991awd]

No, it is not just cosmetic. The car has had the coolant drained for about 2 months because I have been working on the car, so there is no coolant in there.

What happened was the drill bit tore that one passage in the core. Even if I straightened the fins out, the passage is still torn so coolant WILL leak if I fill it up.

I really don't want to drop another $200 for the radiator. It is aluminum so I don't know what to do about it. Maybe some JB Weld like suggested? I can cut the fins and then plaster that area with JB Weld or something.

 

[tsi1991awd]

The extent of the damage was just on that one passage. This is a double row core and the inner row wasn't affected at all.

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Ended up putting JB Weld into the passage on the top and bottom and crimping it then adding JB Weld to the outisde. Looks like ass in the pictures but I cleaned up the excess mess I made. Hopefully it holds...it's only seeing 16psi in the cooling system.

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[1badpurple]

If you want I have a stock one ill sell you really cheap, I have no use for it.

 

[tsi1991awd]

I also have a stock one in the back yard....it's leaking a bit.

But by the time I pay you and have it shipped all the way to WA, it would be cheaper to get a cheap stock replacement locally.

Thanks though man...if this doesn't work out, then I will have to do something. I like the aluminum radiator but can't see spending another almost $200 for one.

 

[Ripley]

Hopefully the JB Weld will hold but I have a feeling you're gonna have to replace it at some point.

 

[tsi1991awd]

I am thinking of applying one more layer to the outside and a bit further down/out for some extra strength. Not sure how much it'd really help but it's worth a try at least. I forsee having to buy another radiator in the future but I want to do everything possible before having to drop the money again....I have sunk a lot into the car already.