Radiator "mod", need advice.
 

Let me just lay down the facts as concisely as I can first.

Bought/installed a PWR radiator.

Somewhere down the line I took the overflow nozzle off.

When I screwed the nozzle back on, it simply broke (aluminum is SOFT).

E-mailed back and forth with PWR, never really got anywhere.

Eventually took matters into my own hands.
I sized-up the nozzle threads, cut the tip off a screw, and drove it from the inside outward to push the nozzle remnants out so that they would not fall in.

I must have spaced out, because I drove the screw far enough that the head cut into the filler neck. That's not my problem. I just use a 16lb cap with extra cap gasket. My problem is I need a new option for overflow. After literally screwing up my radiator I decided to just seal the hole and be done with it. I used that same screw, put it in from the outside and used a high-temp thread locker so that thing is not going anywhere unless it gets torched out.

Figure 1

I am getting a very slight leak from the hoses. I have just replaced OEM hoses that were leaking with silicone, which are now leaking extremely slowly, something like a few ounces every hundred miles.

Now here is what I need to know. I ran across some inline filler/overflow necks and would like to install one into the upper radiator hose. Will this even work, or will I be wasting my time?

Figure 2:
http://streetdreamsbyross.myshopify....nt-filler-neck
or
http://www.jegs.com/p/CSR/CSR-Billet...51516/10002/-1

Re: Radiator "mod", need advice.
 

Where exactly are the hoses leaking from?

The inline filler cap adapter seems like a solid idea to me, there are a decent number of cars that are like that stock. Just make sure you order one that's the right diameter.

There is just a slight seep at the radiator end of the top hose, at least that is where the hissing noise is when I pop the hood after driving.

What I'm not sure of, is whether the pressure in the upper hose differs significantly from the much larger opening in the radiator, and if that might trigger the cap open and just pour coolant out.

Re: Radiator "mod", need advice.
 

most any real radiator shop will be able to repair it by welding a new bit onto the filler neck.

Sounds risky and costly. We don't exactly have our pick of the litter of shops up here in frontier land, though.

In fact I'm not entirely sure there is a "radiator shop" within 100 miles of here, but I will look into it.

--
I'll be damned, looks like there is a couple places. No official web sites, hard to say...

Re: Radiator "mod", need advice.
 

basicly any place that can weld aluminum should be able to fix it, just radiator shops should be cheaper than aircraft or most fabrication places.

Re: Radiator "mod", need advice.
 

No kidding they're going to leak. There's no place for the excess pressure to escape now that you sealed that hole.

Re: Radiator "mod", need advice.
 

If you stop the leaks, there is no reason that this will not work if you can connect the overflow tube properly!

Keith:cool:

Re: Radiator "mod", need advice.
 

Would this option work for you?

Airsept Permatube

I have used these before and had great results.

I am not sure how they would work on an aluminum neck, but if the diameter was correct, I can't see a problem.

The kit gives you everything you need to make a leakproof seal

Re: Radiator "mod", need advice.
 

You must stop the leaks for anything to work properly...

Keith:cool:

Re: Radiator "mod", need advice.
 

I've been running on minimum coolant levels to keep the pressure down. You can see the entire top of the radiator is empty.

I'm operating under the theory that this will stop the leaks. ;)

Now that's an interesting solution. Worth looking into. Only problem I may have is getting the screw out.

Re: Radiator "mod", need advice.
 

NAPA has a similar product called TubeMedic

http://www.napabeltshose.com/images/...eMedic_web.jpg

Either of these products will allow you to relocate your overflow outlet to another part of the radiator neck, so screw removal should not be a problem if you have to leave it in there or seal it.

The Airsept unit is available on ebay. Click HERE


.

Went to Napa to see what they had, the guy I was talking to took a look at my situation and gave me a couple shops to try.

http://www.greertank.com/

http://www.alaskarubber.com/

Solved. :)

Re: Radiator "mod", need advice.
 

Ain't too pretty, but looks like it ought to work pretty good.