[denrep]

This is probably a candidate for a cold (epoxy type) repair. The trouble is, the radiator belongs to a customer of a customer and it probably will be difficult to monitor the repair's success.

As far as a hot repair goes, if practice on a scrap radiator proves that the repairman is proficient at tube soldering, then soldering the injured tube could be attempted. Of course followed by a pressure test and in-service monitoring.

If you can't master tube soldering, the injured tube should probably be abandoned and its openings in both headers closed.

Per this method:
View attachment 54561
But that was simple lead soldering of brass radiator.

Myself, I don't know of any silver solder alloys that will bond with aluminum, and have only had limited success with aluminum solders, so for me, I'd say it'd have to be a weld at the header. But then heat control would be critical to prevent adjacent tubes from loosing there bond with the header. So maybe the latest greatest solder would deserve the old college try.

Whatever the method, you'll have to start with extracting the damaged tube, leaving a clean header opening to work with. Start by neatly cutting the damaged tube, but first warm the fins to break their bond with the portion off the tube that will be removed -and now the tough part- gently warm the header so that the cut stub of damaged tube can be pulled from its socket. Then it's clean clean clean.

With all that being said, it looks like Project7Studios is working on an expensive custom radiator, complete with welded tanks... maybe it should go to a radiator pro.

Although if anyone has some proven sure-fire aluminum soldering tips, we'd sure like to see/hear 'em.

Good Luck

 

[denrep]

. . .I have read of a method using JB Weld with a thinning mix to make it flow a bit easier. I pinch the flue, mix the JB weld, Mix in a bit of mineral spirits (or laquer thinner, i forget) to make it more viscus/loose and then pour it all over the pinched hole. The JB weld is supposed to create a total seal over the hole by penetrating past it but it also renders the surrounding area of the radiator useless by blocking air from passing through.

Has anyone tried this method?

I can report a successful epoxy radiator repair. It's a semi-tractor that somehow picked up a stray stone or something that poked the radiator.

The repair was made with epoxy; the type that's sold in a two part "pastry roll" that is kneaded to mix it. I'm not sure of the brand name right now, but it's good stuff. Seems like the fix has been in service at least two years without a problem. However, the original leak was small, and should the patch fail the truck has automatic shut-downs for low-coolant or overheat.

But it would be a touchy situation to make such a "quicky" repair for a third party, on a radiator that's not under your supervision. Who knows the dollar value of the attached engine.

Good Luck

 

[denrep]

Denrep:
Was the repair on the flue similar to my hole? Or was it located somewhere else?

Also, was it the same stuff people use to quick repair in home plumbing?

The injury was almost identical, but further from the tank.
Actually there's another slightly older repair still holding also. I can post pictures next week.

Sorry I can't recall the name of the stuff. Its sold in a clear plastic tube with instructions wrapped around the hot-dog shaped two part chemical -core and outside- which are separated by a sheet of paper or foil. You cut off a chunk and start kneading, which mixes the two parts, the paper or foil separates out and rolls into a ball. Maybe someone knows the name?

Good Luck

 

[denrep]

I've seen the TV and carnival demonstrations of aluminum (zinc) solder making all sorts of repairs, but I've never had any luck with it except on the bench with a simple flat test plate.

The MuggyWeld flux definitely looks interesting.

Good Luck