Modifying an aluminum radiator

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Hello everybody,I am currently involved in an automotive project that seems to be never ending. I've decided to go with a V-Mount intercooler which means the radiator needs to be reconfigured.I'll need to modify one of the end tanks and relocate both hose nipples.Are there any special considerations due to the fact that the core is brazed together?And what alloys of aluminum should I expect the radiator to be made of?Its a Koyo racing radiator.Thanks in advanceVictorDon't talk about it, Just do it!
Reply:There's been a few aluminum radiator mods/repairs posted here but I think it's safe to say 4043 would be the filler of choice for the job.I personally haven't done any so I can't offer anything on the core question other than manage your heat.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Is it the cast type, or sheet type?I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:I've moded a few Alu rads not overly sure what alloy they are. I used 5356 filler and keeping the heat down is a most do I used a bucket of water and rags welded some cooled welded some more cooled you don't want to melt the solder on the core.
Reply:Why did you chose 5356? I just relocated 2 tabs on a aluminum radiator and tried it at 155 amps and got no where. Rewired for 220v and used 220amps and it welded great.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by weldermikeIs it the cast type, or sheet type?
Reply:Most likely 6061
Reply:5356 is a stronger filler etc and it's what I have I lock my 4043  away so someone doesn't accidentally use it to weld a fuel pipe on a boat. Id say the tanks are probaly a 5000 alloy a 6061 wouldn't like to bend and doesn't have the se corrosion resistance as the 5000
Reply:I have to do a mod myself soon.  Was told that 5356 wasn't good of applications where temps would be over 200* for any period of time.  Then Shovelon said he's welded pistons with 5356 and that was hogwash.  Which is the right alloy?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:I modded a aftermarket radiator for my sa200 , needed to position inlet and outlet on same side, I used 4043 and haven't had any problems yet.As you can see in the pic I slotted the end tank and welded in a divider to force the coolant through the core than back to the outlet. ive also done a few plastic tanked radiators to aluminium end tanks and used 4043 with no problems.This is the one for my dodge cummins I also made a custom shroud and did dual ford tarus sho fans.
Reply:Thanks again for the response,That is very similar to what I need to do.Did you do anything special to manage heat to avoid problems with the brazed core? And besides the 4043 filler what alloy did you use for the patch over the old neck location and the divider?Victor
Reply:I didn't have a problem with either core handling the heat , their both in service today leak free! Not sure on the alloy I used for patch / end tanks It fore sure wasn't 6061 it was a alloy that was able to be broke , ill try and find out for you, it was left over on another project. It was 5052Last edited by spooled05; 01-09-2014 at 03:21 PM.
Reply:Thanks, this is good info
Reply:So what is the operating temp of that radiator, 165 degrees or so? Either filler should be fine.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by shovelonSo what is the operating temp of that radiator, 165 degrees or so? Either filler should be fine.
Reply:The operating temp on truck is 190 deg. and welder is 180 deg.
Reply:I have done A few radiators, air intercooler and oil intercoolers for large excavating equip. I had everything fit correctly and welded most of them with 4043 and the right amount of heat to get the job done quick, never had a issue with the sealant from the core company from the tubes to end plates.  Get a puddle started and get after it, dont linger around with low heat, which puts more heat in the piece to accomplish the same job.
Reply:I've done several radiator mods with 4043 - brackets, tabs, bungs, and reclocking filler necks.  It works well with 2000, 3000 and some 6000 series aluminum, wets out better, and is less prone to cracking.  The only benefit to the 5356 for this application is marginally higher shear strength, which as thin as the tank ends are, is a non-issue, as your fillet welds will be more than adequately sized.  I've never had a need to insulate, cool, etc, and end tank while welding in the proximity of the filler neck to address core problems.  Keep in mind,most end tanks are welded TO the core after it's already been furnace brazed...
Reply:Originally Posted by SupeI've done several radiator mods with 4043 - brackets, tabs, bungs, and reclocking filler necks.  It works well with 2000, 3000 and some 6000 series aluminum, wets out better, and is less prone to cracking.  The only benefit to the 5356 for this application is marginally higher shear strength, which as thin as the tank ends are, is a non-issue, as your fillet welds will be more than adequately sized.  I've never had a need to insulate, cool, etc, and end tank while welding in the proximity of the filler neck to address core problems.  Keep in mind,most end tanks are welded TO the core after it's already been furnace brazed...
Reply:Originally Posted by abec5356 is a stronger filler etc and it's what I have I lock my 4043  away so someone doesn't accidentally use it to weld a fuel pipe on a boat.
Reply:You will be using the heliarc process to weld the radiator with pure argon, no one will be using a dual or tri mix helium tank to work on that thin of a material unless they do not know what they are doing.
Reply:Ok, so I'm good with the welding and filler material.Since I don't have access to a brake, I expect to cut out and piece together the parts I'll make.Is there any good reason not to use 6061 other than it's lack of formability?
Reply:I am glad to report that the aforementioned modifications appear to be a success!I cut the radiator up, Fabricated some new parts, and welded it back together.Used 1/16" 3003 sheet, and 4043 filler.To make sure that it is not leaking, I made up some adapters and pressurized it to 20psi and checked for leaks in a tank of water. I did find 4 very small leaks where some of the welds overlapped. But I welded those up and left pressure on it overnight, and it did not loose pressure. My concerns about creating problems with the brazed core did not happen. So now I just have to finish the rest of the modifications on the car and get it running.I'll post a write-up in another thread in the coming days to show the process.Don't talk about it, Just do it!