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Plastic radiator crack

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pvfdpinky

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Small crack about a inch long just thin enough where I can barely get a finger nail in the crack. On the top plastic part of my radiator. What is the best epxy to seal the crack given the radiator gets hot and is pressurized

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NYBODYMAN

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Maybe JB Weld? I wouldnt trust anything short of a new radiator though. Just my opinion.
 

Bigblockyeti

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Are you looking for a reliable fix or just trying to make it last long enough to unload it? I used high temp RTV on a crack at a the top of a radiator similar in size to what you have described. Just enough was drained to keep that area dry, cleaned with acetone and blown dry before application then allowed 48 hours before it was tested with the cap loose (no pressure). I was driven 700 miles over the next couple days to get home with the cap left loose. It was chilly and at highway speeds didn't cause any cooling issues.

If you need a repair you can count on, it really will have to be replaced. Plastic radiators are thing for the sake of being cheap and lighter, not for longetivity in the engineered to fail world we now live in.
 

Jking24

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I repair them somewhat frequently with plastic weld two part epoxy. You need to get it clean of all coolant and rough the area up considerably with 60 grit
 

Adam R

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JB Weld can work in pinch, or for quite some time in my experience. I used a combination of JB Weld and fiberglass drywall repair mesh and built it up like a fiberglass repair. Scuff up the repair area and clean the plastic really well. It actually held for well over a year, but eventually started seeping again. After nearly 20 years and untold number of heat/cold cycles, even plastic has its limits. I finally replaced it with a new radiator.
 

mfewtrail

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Radiator shops can replace those end tanks, but the cost is probably not too far away from a new unit. Another consideration is the condition the core is in. If it's old + full of scale and buildup, just get a new one. Radiators are far cheaper now than in the past, especially online.
 

gregs

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Have used a product called Stic-Tite before and it has worked well.
 

Bill Bowman

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There is a welding process for plastics. Most common is airless (equipment costs way less) and a universal welding ribbon. Works fairly good on bumper covers, but I have no experience with plastic radiator tanks. Typically, replacement radiators are not crazy expensive, plus the fact that your radiator may be nearing replacement anyway, I would just replace. Why did it crack?
 

samss

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Flex Tape!!
It actually held up for a couple of weeks until I could replace the radiator. None of the plastic repair stuff would stick for me.
 

yeldogt

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Radiator shops can replace those end tanks, but the cost is probably not too far away from a new unit. Another consideration is the condition the core is in. If it's old + full of scale and buildup, just get a new one. Radiators are far cheaper now than in the past, especially online.

The last time I checked it was as much as an OEM new.

I had to get a new one for my old W210 wagon -- OEM was under $200 ...
 

jubilee

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Seal-All. Then rough up and cover with stranded fiberglass resin. Has held for over 10 years in motorhome with 460 Ford.
 
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nadogail

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Where to start?

If I had a broken plastic thing I wanted repaired my first choice would be a Plastic Fabrication shop.

I have successfully repaired some plastics with JB Waterweld, a two part epoxy stick that you knead together until the color is uniform. I have used it to patch a hole poked in a plastic shower stall. It also patched a hole in a washing machine. I have also used it to plug holes drilled in a van roof where a previous owner had removed a bolted on rack.

An equivalent product is Pig Putty.

Realistically IMHO, if you want long term results a replacement radiator is your best permanent repair.
 

kelpaso1

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Plastic welding is the only reliable repair. Glues and epoxies simply do not work long term. I have welded many cracked rad tanks that are still good 5 yrs later. BUT, the problem with radiators is the constant pressure and de-pressure cycles that causes the cracks. After a few years of this the plastic (or should I say ABS which most tanks are made of) deteriorates, so fix a crack and another one happens somewhere else on the tank.
 

BroncoRaider

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Small crack about a inch long just thin enough where I can barely get a finger nail in the crack. On the top plastic part of my radiator. What is the best epxy to seal the crack given the radiator gets hot and is pressurized

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If you have one crack, more aren't far behind. Get a replacement radiator and a few gallons of antifreeze. It only takes an hour or two to swap it.
 

Tcounty

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I bought one of the air plastic welders from Harbor Freight a few years ago. I haven’t welded a radiator but everything I’ve welded has held. I’ve welded several spray tanks.

I think it cost around $75
 

bwringer

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In these situations, I always use a rectangular plastic tool found in my wallet with an assortment of numbers that allows me to order up a replacement.

FWIW, shipping is a complete crapshoot. You can save a few bucks ordering online, but shippers looooove to ruin radiator boxes. They're all swamped this time of year, too, so I'd order up a new one from a friendly local auto parts purveyor.

I've always found that once you get a leaky radiator out, you'll wonder how it's held together this long, and you'll be happy you're replacing the whole thing.

If you need to limp along a few more days before the replacement or time are available, various plastic repair techniques have been discussed.

I've had "good enough" but temporary success with cleaning thoroughly and using a Devcon epoxy intended for plastics.

Any sot of adhesive or epoxy WILL fail sooner or later. But they can work for a while. Just don't go far from home, keep a close eye on things, and carry a jug of premixed coolant.


Plastic welding can work, but unless you're dealing with some sort of accidental damage on a fairly new vehicle (like leaving a tool lying on top of the radiator and closing the hood on it) it doesn't change the core issue, which is that the plastic is old and brittle. So even if you manage a successful weld, you'll soon have another crack, and/or the seals will start leaking.
 

toolin' around

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I would never consider a "permanent" repair... particularly a DIY one. I assume there may be a professional plastic welding process and pressure testing service that might be available in the radiator industry... based on testing and experience, not a one off "give it a try". I would be sweating on every future road trip that it's going to fail. Just replace it.

Having said that... I did blow a split in the top tank on my 1997 E350 box van coming up the Grapevine just north of LA late at night... I had JB Weld in my toolbox, but it was the regular set, not the 5 min stuff (rectified that now!) Also had a pack of "Steel Stick" epoxy putty (super handy for repairing broken side cases and brake levers on the dirt bikes!)... scraped out the split in the radiator top tank so it was opened up a bit and roughed up the surface and pressed the epoxy putty hard into the crack to try to get in into the crack deep enough to expand a little on the inside to key it in place. Held fine for the next hour or so to get me home, and then to the workshop to replace the radiator (and all the hoses while they were easier to get to.

I would never have trusted it long term, I'm sure the two materials would expand and contract at different rates, but it was an effective emergency repair... the epoxy putty sets within 10-15 mins.
 

Loose Nut Buster

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When I cracked mine , I put a piece of aluminum under the shroud and pop riveted it in place w/black rivets. Almost non detectable, I would think/know the epoxy or most any type adhesive would just crack again if leaned on, even a little.
Just my two $$

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Jazz1

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I have yet to see any repair on a plastic tank work, the expansion and contraction of the tank is the reason glue won't work.

JB PlasticWeld flexes. Common for repair on snowboards but not sure if it will adhere to radiators. My only experience with cracked plastic rad, we replaced it.
 
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