Radiator Core, Aluminum

The only approved repair method for the aluminum radiator core is to use a two-part epoxy material.

The materials and supplies necessary to repair the aluminum core are:

• No. 200 Crimp Clamp. The Barbee Co., P.O. Box 323, Louisville, KY 40201.
• Epoxi-Patch Kit No.6C Aluminum. Hysol Division of the Dexter Corporation, Olean, NY 14760.
• Sandpaper and/or emery paper, 80 or 100 grit.
• Stainless steel wire brush No. 23151 or equivalent. The Milwaukee Brush Manufacturing Co., Menomonee Falls, WI 53051.
• 375 watt heat lamp.
• Mixing card and spatulas.

Procedure

 CAUTION: Do not use wire brushes that are not stainless steel. Use of wire brushes which are not of stainless steel may leave a residue on sealing surfaces, which may not allow the epoxy coating to adhere.

1. Thoroughly clean the area around the leak with a stainless steel wire brush and, if necessary, emery paper to get to hard to reach areas. Use the brush on the epoxy coating as well as on the aluminum.
   
   
   
   

   NOTE: Observe all cautions and warnings printed on the repair material containers.

2. Squeeze a bead of repair material (long enough to repair the leak) Part A (resin) on a clean, dry, disposable flat mixing surface. Use uniform pressure to obtain an even bead.

3. Squeeze an equal length bead of hardener (Part B) parallel to the Part A bead.

4. Mix parts A and B together.

5. If it is necessary to have the epoxy flow to obtain satisfactory results, warm the core around the leak with a 375-watt heat lamp. Then apply the repair material to the leak.
   
   
   
   

6. Position the 375-watt heat lamp, 305mm (12 inches) from the repair and allow to cure for two hours. DO NOT position the heat lamp closer to the repair than 305mm (12 inches). DO NOT use a heat gun or overheat the repair material.

7. Leak test the repair by clamping the tank to the header with No. 200 crimp clamps or equivalent. After a successful leak test, install the radiator tank as outlined.