Big Dave

Dave....you may be launching a new side business. This is how most of them get started around here.

chaadster

Dave,

That is simple--just remaking the preexisting part--but it is really pretty clever! It must have been time consuming, though, hand-notching the metal.

Does this mean you'll be bringing that gorgeous car down on Saturday?

SwayBar

Nice job!

perrys4

I have no confidence in the plastic tanks. Nice work and a great idea. Hope it works for you.

Imo000

Nice one!

You could take the rad into any radiator shop and have them pressure test it. This way you'll know if the rad hold up at the maximum designed pressure.

atb

What an awesome fix, nice work. (and very marketable )

jpitman2

What is your clamp/clip made from? Looks like alloy from the swarf on the bandsaw? Is there a standard extrusion section of the correct size available, which might be stronger than cold bent alloy?
jp 83 Ero S AT 50k

Jascd

you can guess how I feel after having to discard my "unrepairable" behr and replace it with an after market version. You could sell those clips for $200 and have people lining up.

Very well done.

Stephencs601

After all that time and effort could have bought a new one piece unit and be done with it.

backnblack

Dave has been trying to convince me that we should make these and sell them to people on Rennlist so can we take a poll.
1. Would peolpe here pay 200.00 for this.
2. How many people have needed this for there car.

3. Before Andrew reminds me I'm sorry Dave for high jacking your thread
Regards
Matt

Mike B

Just a thought...but why don't you start a new thread / poll with different price points. It might give you an idea of your market.

davek9

First thank you all for the encouragement, like Matt said doing fun projects like this justifies us having all these tools..!

Well the morning started out with a thorough cleaning of the radiator inside and out, including the oil cooler. It had spent over a week inside a heave duty trash bag in the back of my Grand Cherokee and I did not want to take any chances.

I thought of having it pressure tested, but returning to one of the ten shops that laughed and said “oh no… that’s a German radiator and you can’t fix them over here” and giving them my hard earned money AND letting them see how to do it just did not sit right w/me.

The install was a breeze; this has got to be one of the easiest things to do on our cars, having the correct wrenches for the oil cooler lines are a must.

We don’t need no stinking tabs….!

After several times up to temp I am pleased to report the radiator is desert bone dry with no signs of leakage from the Header Tank seal.

However now that I know the fix works, I am willing to spend another $90.00, I would much rather have an “X” pipe!
So taking the advise of Mrmerlin (thank you) I am ordering a new tank w/seal from 928 International, as with this method of repair all but the tie-wraps are re-useable… over and over again.

Matt and I are looking into a small production stamping run; he does not believe it will be cheep though.

For me making something, the discovery process, re-thinking the original from what we learned and actually doing it is almost as fun as driving a 928!!

Bill Ball

I've noticed that if the tanks sit around off the radiator for even a day, the sides warp in. Yours seemed to do that too. How did you get the walls straight again?

davek9

Popped one side on pushing it from with-in and then pulled the other with a little "L" hook driver, they fit into the channel.
Matt and I noticed that too, I had to go back and look at pic I took when I first removed it, would never have thought the plastic would warp like that, so it wasn't sitting in the back of the car for a week thst did that..

davek9

Update, I removed the Rad (30 min's), then went over to Matts' and we R&R the Header tank with a brand new one from 928 International (thanks Jim!) that took ~2 hr's.
I installed it tonight after work and went for a cruse the w/AC on... got it nice and hot

No leaks yet, heading over to Ann Arbor tomorrow w/ the local 928 gang so I will keep you all posted on how this fix works out.

Also if you noticed I did not use as many ss tie-wraps this time, not needed, the header tank "clip bars" are stiff and won't move in the middle.
When we did the R&R the "Clip Bars" did not come off as easy as I thought they would.

Thanks for your support!

Dave K9