I guess this procedure works. Radiator in. Fan switch in with new electric fan.

It all works.

NO LEAKS!

No puddle of antifreeze, or oil, or power steering fluid.

Wow. first time ever!

And put in a delco alternator while I was at it. At idle with the fan on....13.9V at the jump post!!!!!!!

Again, if you anneal the tabs before bending then you will have less issues.

I'll probably get kicked out of the DIY club but I just went ahead and bought a new radiator to be done with it. Something rattled around in my head about not trusting 20 year old plastic.

I just couldnt rationalize spending another grand when I had the new end tank sitting in the garage. I really wanted put in a new rad, but my wife would have seen the delivery, figured out how much it cost and promptly headed off to Neiman's shoe department to stimulate the economy.

In my case, I just checked the Yellow Pages and found a shop that mentioned Behr radiators in their ad. I guess I lucked out. I called and they said they were very familiar with plastic sidetanks. Thet pressure tested the radiator for free and showed me the leak. I provided the sidetank and seal (from 92 Intl). They charged me $90 to replace it which included "rodding" the core. About 2 years later I had an over heating problem that swelled the right side tank and started a leak at teh seal. So, I had them do the job again. They noted I probably should have an all aluminum racing radiator which they said they could build. I probably should have priced that. This was a local father and son shop that I gather has a great reputation.

Good job, Dan.

Bill, please share the name of the shop. Thank you.