messed up my radiator! - Polaris ATV Forum
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post #1 of 4 (permalink) Old 04-23-2011, 08:08 AM Thread Starter
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messed up my radiator!

aargh! i was taking the rad out to move it up to the rack - and the goddamn nipple for the overflow hose broke clean off the rad - leaving only thin aluminum and a 1/2" circular hole...:frusty:

sooo -- am i pooched? i don;t have the cash for a new rad....

1) is this repairable? i figured if i had some metal below i could just drill and tap a new fitting, but can i tap a new fitting if the metal is just thin aluminum?
2) as an option --- can i plug the hole completely and tap the upper rad hose to run to the overflow?
3) if i am F'd -- since i need to buy a new rad, can i use a smaller radiator? it's going up on the rack anyway so i don;t care if it fits the stock mount.

2003 sportsman 600, btw

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post #2 of 4 (permalink) Old 04-23-2011, 04:58 PM
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back in the day when people fixed things and not replaced they would solder or braze that nipple back on i would suggest solder with a low melting point for thin aluminum

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post #3 of 4 (permalink) Old 04-24-2011, 06:56 AM
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Ditto Chopper. I am in the A/C business and they have solder made for aluminum with a flow temp so low you can solder coke cans with it. It will hold 400psi of pressure for A/C condensors. If you can not find it an auto parts house call your local A/C wholesalers.

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post #4 of 4 (permalink) Old 04-24-2011, 08:49 AM
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Or, clean it up really well and JB Weld it.

Tony B.
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