When you cut, Roger, remember there is a frail aluminium cooler right there a millimeter or so away.

 

Roger, might want to let the shop do that part. They should have a tool that straightens and re-crimps the tabs, and if you straighten them yourself it may not be an ideal situation for their crimping tool -- which may lead to extra bending. Bending of tabs should be minimized as much as possible. If they don't have these tools, find someone who does.

 

So is there a reasonable chance of me effecting a DIY end tank replacement? Importing a new rad from one of the Big 3 is not really an option for me.

Does anyone have photos of the end tanks being replaced?

 

I would highly recommend that you take it to a shop that does plastic tank work. I used to work at a radiator shop years ago. To be done properly the radiator needs to be clamped into the jig. Not so much for the removal, but the installation of the tank. When in the jig for installation the tank is pressed down into the gasket and the tabs are then crimped over the tank. They should be able to pressure test the unit when they are done to make sure it doesn't leak.

 

Paul, I would say your chances of making a lasting repair with hand tools is pretty slim. The jig is essential to do the job right, and you only get one shot at this. Once the tabs have been bent out and back one time, the next repair attempt will break some tabe off and it's downhill from there.