DIY Radiator tank end removal
 

The crack above my radiator inlet hose when from seep to spurt.

I called around and found no one interested in replacing the end tanks

So, I figured I'd give it a go.

First, make an inexpensive and easy press.
http://members.rennlist.org/lt_texan/radpress.jpg

Then heat up the aluminum tabs and carefully break them off.
http://members.rennlist.org/lt_texan/radtabs.jpg

The tabs are thick and very brittle. I don't think it is possible to bend these back without breaking them. I bet that is why I could find no one that wanted any part of it.

(Yes, the inlet is broken.)

BTW, i tried sealing the crack with 2 part epoxy - the heat and antifreeze turned it to mush.

I do not look forward to telling my wife I need a $900 radiator.

Dude. I'm sorry. Nice post though. I hope it was intended as humor because I laughed my ass off when I read it.

They can be bent back, although missing the ones you've got broken off, you might not be able to save it. I used a paint can lid remover and grinded it down with a dremel to give it a hook with some meat on on it and the right angle to pull them out.

You should drop an e-mail or PM to Heinrich, I think he said he's got a couple of used radiators laying around.

Good luck.

I might be wrong but I think I recall a post where someone removed the end tanks, ground off all the tabs and reclamped them using aluminium channel sections crimped tight using mole grips or similar.

Yup, I remember reading that too. I'm sure it's here somewhere.

If only those two are broken off, then it may be salvagable still. Being at the corner, there's enough compression from nearby tabs to keep a seal.

Saw through the plastic end tank to remove all of it except the rim that is held down by the tabs - that'll improve the access to the tabs, and you can heat then with a blowtorch. Then bend the tabs gently upwards using a flatblade screwdriver (easy to do with a screwdriver once you've cut the tank body off its rim). You don't need to bend them up to 90 degrees - once both sides are up 60 degrees or so you'll have enough play to get the rim out, and put the new tank in.

Once there's no rim, go have a beer - you'll deserve a break :)

Then come back, heat up all the tabs again with a blowtorch to make sure they're as pliable as possible, and then put the new tank in place and clamp it down. You don't need to clamp the radiator until you're squeezing the new tank on to compress the gasket and fold tabs down again.

For the tab folding, I use a pair of channel lock pliers and do several passes of small squeezes.

yeah it was intended to be a bit tongue in cheek. This just seems like territory no one wins in.

I've done a good job of breaking and tearing off (most of) the end tank with a pair of channel locks and a screw driver. This exposes the tabs.

WE"LL SEE HOW THE BEND NOW!!!!!!

What the hell. Nothing to lose.

And bad timing, just gave my wife hell for spending too much money.

ps, I did see the thread on the homemade tabs.

I almost pissed myself when I read that line: "Carefully heat up the tabs and break them off." I may have to sig that one. :thumbsup:

Good luck and keep us posted.

Search for user davek9. He did a complete writeup on how to repair the end tank.

Here's the link to the no-tabs repair - had it filed in my subscriptions' "Cooling" folder.

https://rennlist.com/forums/928-foru...h-no-tabs.html

Yeah, Dan, I'll rub it in. I had my passenger sidetank replaced twice by a radiator shop. No broken tabs. Apparently they have some nice tools for this.

Bill, I'll call around some more on Monday to find a taker on the work. (Before I do too much damage:eek:) Online I did see a few I could ship it off to.

The secret is to remove the tank before you bend the tabs. I used channel locks to crush it and break it. Dikes to trim what I could and even a razor knife.

The trick is to get the tank off to get good access to the tabs.

Using channel locks, bend not just the tab, but the tab and frame back. Channel locks on the end of the tab and under the frame works just fine. The tab will bend a bit and the frame will bend a bit, not stressing anything too much.

Fit the end tank without the o-ring to ensure the tabs do not restrict the tank from seating properly. Be careful to allow just enough access.

I put in the o-ring, tank and used my press to compress the tank where it belonged. I could see this by looking at the other tank.

Once in place and under pressure from the press, I used a hammer (yes, for the weak at heart, a hammer) to tap the frame back up against the tank. I took my time and held a 5 lb sledge on the other side of the frame to absorb the impact.

The tabs closed in as you tap the frame back. I finished the tabs off compressing them into place with channel locks.

Obviously, I took my time and did this in many rounds, not trying to complete one tab all at once.
http://members.rennlist.org/lt_texan/radtank.jpg

Since I am installing a 16" electric fan, and understand the temp switch on the rad is a bit on the high side, I will not pressure test the radiator until this is done.

And that is because my pressure tester happens to be a 1978 Porsche 928 supercar!

You shouldn't need to ship it. Just find a shop that has experience with Behr plastic sidetanks. Most shops should. The one I used was good, but I needed to provide the tank and gasket.

I'm a staunch DIY guy too, but I left this to the pros.

Bill, I checked around by me and got attitude when I brought the radiator in along with the side tank and gasket. No one wanted to mess with it so I did it myself.

Maybe it depends on where you are.

ditto. everyone wants to make the big bucks. no time for the bread and butter jobs around here.

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.