How to Repair a Plastic Radiator

There are some things you should be aware of if you would like to repair a plastic radiator, which is likely to be the case if your automobile was manufactured in the 1990s. The traditional radiators do not process fuel as well as plastic ones because they are relatively heavier.

Although many people believe that it is easier for the plastic radiator to break down, this is not really true. Leakage in the storage tank is what usually leads to the breakdown of the plastic radiators. Although the cores of the plastic radiators are usually very good, the tanks tend to be weaker.

It is welding these cores that make plastic radiator repair challenging. It may be better to replace the radiator if the damage to the core is extensive.

Fortunately, most of the damages to the plastic radiators involve the tanks. If you would like to repair the tank, then you will need V groove tool, screwdriver, wrench, pliers, heat gun, air-free plastic welder, and nylon-based welding rod.

Find the damaged part after disassembling the plastic radiator. Disconnect all tubing that may become entangled during disassembly. Check the whole surface of the tank for any signs of damage. Fill the tank with water if necessary so that you can determine the leak.

Determine the leak’s dimension using the V groove tool, which will also help you to position the air-free plastic welder well.

Use a heat gun to preheat the area before you apply the welder. Then weld the leak by melting the nylon-based welding rod.

The cost of plastic radiator repair at an auto body shop is fairly high. If you are interested in fixing a cracked plastic radiator, therefore, you can consider doing it on your own. So long as you know how to go about it, you will find that this is a relatively simple process that will save you precious dollars.

Different sections of the plastic radiator may develop faults, leading to leakage. One of the first steps you need to take is examining the fittings leading to the radiator. If the leakage comes from the radiator, then you will need a screwdriver, soldering iron, tooth brush, acetone, hair dryer, black tie wraps, and a marker or tape.

Understand the plastic radiators

When dealing with plastic radiators, you should not use adhesive, as the pressure and temperature will render it ineffective. You should therefore have a good understanding of how the plastic radiators function.

Penetration

Getting good penetration is important when you weld the tanks and you should preferably use a V grooving tool. Alternatively, you can use the tip of the welder. The glass fibers used will produce crackling sounds and this is normal.

Preheating

It is a good idea to preheat the nylon using a heat gun because of its high melting point. Point the heat gun towards the area you expect to work on until the plastic turns glossy and then allow the heat to get through.

Welding

Remove the welding rod and melt about an inch. Separate the welder and the rod and then work the melted rod inside the nylon. Do this until you get one color, which means that the mixture is good. Melt an inch of the rod at a time so that you can work on the nylon before it cools.

Finishing

• Smooth the area as much as possible using the tip of the welder.
• Then take the following steps to repair the cracked plastic radiator.

Find the crack

Allow the engine to run so that the temperature rises normally. Sufficient pressure will build up after about half an hour. Shut the engine off for the pressure to force the coolant out of the crack. Use either the tape or marker to mark the area of the crack.

Let the tank cool before removing the cap and check whether the crack is below or above the level of coolant. You will need to drain some coolant if it is below the level. Ensure that you have fresh coolant handy before you do this.

Prepare the area

Use a toothbrush and some acetone to clean the area and dry it. Turn the hairdryer on and then hold it close to the crack until the area gets completely dry. Scrub it before blowing once more.

Repair the crack

Press the soldering iron’s tip to the tie until it starts melting. Wrap the tie into the crack by pressing it. Melt one spot so that the tie and neighboring areas turn to liquid.

Let the hot liquid harden before cutting off unused parts of the tie.

Repairing the Plastic Radiator Outlet

Although you should always be careful when carrying out any repair, you need extra precaution when you are repairing a plastic radiator. In many instances, you should just install a replacement radiator. However, depending on the damaged part, you may also carry out repairs. For example, there are different parts in the plastic radiator outlet and you just need to replace the faulty part.

You will find it relatively easy to do this if you have a socket wrench, manual screwdriver, screw extractor, new plate, new screws, and pipes of various sizes.

The plates on the plastic radiator outlets are usually held in position with two screws, which may get stripped. You can easily replace the stripped screws.

Check the damage on the screws you would like to replace so that you can determine the appropriate tool. Try using a regular screwdriver first of all and then use a socket wrench if it fails. However, if you can get a screw extractor, then this is the most ideal tool to use.

Check for any damages on the holes before you replace the screws. Check the plate for signs of damage too. Depending on the extent of damage, it may be necessary to replace the plate.

Check the pipe holes to determine any signs of wear or enlarging, in which case you will need a different size of pipes. In such a case, you will also need to replace the plate.

Although you can carry out some plastic radiator repairs, a time will eventually come when you have to replace it.