Radiator fail

Greg_M

Well-known member
Dec 27, 2021
243
111
Vancouver Island
Last summer I installed an aluminum radiator - a CoolingSky 70mm 4 row core. 1500 miles later I noticed a drip of coolant driver's side. Not much so the source was less than obvious but I did eventually find a crack in the core header. And shortly after that it stopped leaking altogether and I continued to drive it while I had the original rad rebuilt with additional cores (at ~ 4X the cost of the CoolingSky). Really hoping this is the final chapter in this saga. Below is a close up photo of the crack.
crack.png
 
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terryjm1

Well-known member
Jan 23, 2011
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381
Ughh…I have one of those. Time to find a good radiator shop to refurb my old original ones. .Including myself, I know of 3 who have them, mine being the only one not yet failed.
 

Greg_M

Well-known member
Dec 27, 2021
243
111
Vancouver Island
I did contact Ron Davis but there was an error in their quoted dimensions they were slow to clarify and I'd already gone with the CoolingSky. I'm not convinced aluminum is the best material choice for a radiator to be honest (unless you're racing and the weight saving is important). The cores and headers are impressively thin on a large planar assembly that shouldn't be allowed to flex much but...
I started out looking for another OE radiator to have rebuilt before my original rad came out but had no luck at all. Looked at a few parts trucks but the folks selling thought everything Land Rover fit every other Land Rover. I just couldn't spare the use of my D1 while the rad was out hence the CoolingSky experiment. So here I am full circle with what I wanted to start with.

PXL_20230330_223756970.jpg
 

Greg_M

Well-known member
Dec 27, 2021
243
111
Vancouver Island
Including myself, I know of 3 who have them, mine being the only one not yet failed.

Would you know the failure type for those three Terry? With the exception of the nozzle fillets the pressure boundary welding was good on mine. The structural welds on mine were noticeably worse. The forming process for the core header is at fault in my case.
 

robertf

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Jan 22, 2006
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Im mostly pleased with my recored 4 core brass. I had to clean up the uncurable rustoleum the shop used.

its keeping the most unloved 4.0 at 180F with the AC on and husky blocking the grill

I haven't installed the alisport one yet, but it looks better than the amazon version
 

terryjm1

Well-known member
Jan 23, 2011
1,499
381
Would you know the failure type for those three Terry? With the exception of the nozzle fillets the pressure boundary welding was good on mine. The structural welds on mine were noticeably worse. The forming process for the core header is at fault in my case.
Unfortunately, all I know about the other one is that it leaked.

Fortunately, I have a low mile original radiator in storage that likely just needs a boil out and pressure test. The reason I didn’t do that instead of the cooling sky one is because I live in a very rural area and there are no radiator shop for at least 100 miles. In the “throw away radiator” era there just isn’t much demand in an area with relatively low population.

I have another one that came out of a 26,000 mile parts truck installed in my current project. I would have thought it was 100% but after driving it about 60 miles it has a very mild leak, I believe at the driver side upper mounting bracket. It’s not even a drip, it’s just wet from that bracket down to the bottom of that tank. The other one is going to get tested so I don’t have to do the job twice. If I can’t find a radiator shop to do it I will rig up my own pressure test. I’m thinking compressed air and either a spray bottle with water and dish soap or submerging it in a tub of water.

It’s a bummer the cooling sky one is so questionable as it cools extremely well. The D1 it’s installed in never reaches 190 degrees even when working hard. I will run with it until it fails and have the refreshed original one ready to go.
 

Greg_M

Well-known member
Dec 27, 2021
243
111
Vancouver Island
Im mostly pleased with my recored 4 core brass. I had to clean up the uncurable rustoleum the shop used.

its keeping the most unloved 4.0 at 180F with the AC on and husky blocking the grill

I haven't installed the alisport one yet, but it looks better than the amazon version
It's unanimous then, these rad shops can't paint!
 

Greg_M

Well-known member
Dec 27, 2021
243
111
Vancouver Island
It’s a bummer the cooling sky one is so questionable as it cools extremely well. The D1 it’s installed in never reaches 190 degrees even when working hard. I will run with it until it fails and have the refreshed original one ready to go.
You may never experience a problem. I dye penetrant tested most of the welds and adjacent header metal on mine after removing it and found no issues. My experience might be just bad luck which is why I was curious how others have failed.
 
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terryjm1

Well-known member
Jan 23, 2011
1,499
381
You may never experience a problem. I dye penetrant tested most of the welds and adjacent header metal on mine after removing it and found no issues. My experience might be just bad luck which is why I was curious how others have failed.
Maybe I will be lucky. If you decide to not use your fan setup, let me know. My fan clutch is new and working well but it won’t last forever.
 

Greg_M

Well-known member
Dec 27, 2021
243
111
Vancouver Island
Maybe I will be lucky. If you decide to not use your fan setup, let me know. My fan clutch is new and working well but it won’t last forever.
I'm not sure why but I feel like I should keep the original fan and clutch in case I want/need to put the truck back to stock (unlikely as I'm pretty attached to my electric fans).
 

terryjm1

Well-known member
Jan 23, 2011
1,499
381
I'm not sure why but I feel like I should keep the original fan and clutch in case I want/need to put the truck back to stock (unlikely as I'm pretty attached to my electric fans).
Sorry, I wasn’t clear. I was speaking of the electric fan stuff you installed on the cooling sky radiator. But, if it fits with your soon to be replacement radiator, that would negate that.
 

robertf

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Jan 22, 2006
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Surprise! that £940 radiator doesnt fit
 

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robertf

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Jan 22, 2006
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Im probably going to drop the original off for recore this week

alisport sent a prepaid return, reworked it, then sent it back

Now that it fits the frame I see all the other dimensional problems. Its not tall enough. upper locating pegs barely catch the bracket and the fan shroud sits up so high it wont clip into the notches
 

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