Bret928

Well, actually I'm turning my son loose on my 78''s radiator replacment. (Gulp! )

Anyway this'll be a part of his auto shop grade, I've arranged for him and three of his fellow students from his class to exchange the new Aluminum Radiator I got from 928int. Now I wouldn’t be too concerned if I was doing this in my own garage, as I think I have enough resources (abilities, tools etc) to get myself out of trouble. But because they’re doing this in my son’s auto shop I just wanted to run this by the group here first.

Now I'll be on hand (hands in my pockets) to advise and help out should there be any unforeseen complications. I also have a long list of dos & don'ts (mostly don'ts) for the boys before work starts.

So here is what I've got got on tap for the boys:
New C&R alloy Radiator.
New Upper & Lower Radiator Hoses.
New Crush Ring Blocks 2ea.
New Thermostat & O-Ring.

The only thing I'm not sure of at this poit is the coolant. How much and what type? Also should I use a water-wetter?

I’m also going to make print outs for the students from the section of the CD manual dealing with R&Ring the radiator.

To insure we don't paint ourselves into a corner - I'll also provide the primary tools needed to make the swap rather than hoping that the shop has what we need:
Two wrenches: for the engine oil cooler lines. Primary wrench & backing to hold the one still while the other is loosened & then tightened.
Allens for the hold downs.
And of course some finder covers to protect from any damage these fine young men might cause.

So what do you think - am I missing anything? Thoughts welcome too?

BC

Do you have any empty running springs-type huge 5 gallon gugs for thier water? I use those to mix the coolant (in san diego, I go no more then 25% coolant), plus the requisite water wetter (2 or 3 bottles) mix all that up in equal parts to get to the total capactity, and you put it in the coolant tank slowely, and then start it up and put more in as it goes down.

Bret928

Actually I've got a five gallon water bottle at home - I like that idea!....

But I would have figured you'd try to put some coolant in the block & radiator once you've gotten the lower hose connected. Then close it off (connecting the upper hose) when you can't get anymore in without spilling - then add it to the overflow tank. Did I miss something Brendan?....

BTW everyone - Brendan was kind enough to recommended the finder covers & the allens above.

sharkmeister85

I put one of their C&R rads in my '85 last year . I found I needed to make some "mods" to get it to fit "reasonably" well.
Glenn

Bret928

Thanks. I'll be sure to lay them side by side first and do a test fit.

Did it require any cutting or something like that on the radiator, the fan shrouds or on the car?

sharkmeister85

I found I needed to cut down the rubber pucks it sits on, cut down the little hose on the top fitting to fit as low as possible (would like more clearance there still) and I had to grind down the top flange to get the stock shroud with intake vents to sit lower down. All this in an effort to gain enough clearance so I could close the hood.
Glenn

Bret928

Ok!?!?! Not that got my attention, anybody else have the problem Glenn had with clearance?

I seem to remember seeing some posts about it but didn't think it was a big deal to correct. But I'll keep on my toes when we start to re-fit the new radiator.

Also I plan on bringing my camera to do a photo essay & will post some shots when it's done.

checkmate1996

So what about pressure testing the entire system before and after. Also are you planning on draining the block as part of the swap?

Bret928

Yes. We will be draining the block as well and replacing all the coolant with new stuff.

As for "pressure testing" the system, unless my son's auto shop is equipped to check that, I'm going to trust the good folks at C&R to have gotten it right. If not, I'll be contacting Jim & his friends at 928 International should I have a problem with leaks or what not. Even so I wouldn't want to check the pressure at anything above the rated value of the pressure release cap.

But the truth is I'm pretty confident that I won't have any issues with the new Radiator. Likewise the block seems sound and the only leak I know of is in the old radiator at pressure.

perrys4

Why would 928 intl. sell something that didn't fit in the car without modification?

Bret928

I was under the impression they didn't. Those folks have been great to me and am willing to give them the benefit of the doubt until I know otherwise.

SharkSkin

The top bleed hose was a problem for me -- I went to the auto parts store and found a same-size bypass hose with a molded-in 90° bend. It helped, but it's still not right. I'm still scratching my head over alternatives.

Also, re: mixing coolant: If you have completely drained the block and flushed with clean water, you really don't need to do anything fancy. Dump in your 1 gallon coolant plus water wetter. Fill with distilled water(unless your coolant mfr. says otherwise) until you can't fit anymore in; then just keep adding water as the level drops. This may not get you the same dead-nuts 25% coolant accuracy as Brendan's method(er... B, did you take into account the volume of water wetter? ) but it's plenty close enough.

Alan

I had a 928 Intl rad fitted by my wrench recently and he also noted there were some fitment issues with the existing fan shroud (tight at sides) and the small hose on top has limited clearance... you need to be wary - but it will fit with some work. he actually liked the overall quality a lot - he normally refits Behr - but couldn't get one for 2 weeks - this one has longer fins than a Behr, presumably = higher cooling capacity. Don't know about the bottom issues mentioned - seems he had no issues with that.

You may also want new side tank plug seals (depending on your cars equipment) and you might as well replace the thermo switch - partly proactive - partly its possible to damage on removal from the old rad - better to be sure you can button it all up in one go...

Alan

Bret928

I'll be careful Alan, belive me I'll be checking fit at every stage of the procedure.

BTW I actually purchased an "all" aluminum C&R radiator from the Boys at 928Int. The end caps are aluminum too & actually part of the radiator.

Here's a shot off of 928int.com

BC

Yes, and being an English/Comm Double Major with a religious studies minor, my head still hurts from the math I did to get the real numbers.