Cooling System Complete

After fixing the radiator and re-installing it, I was able to finish out the installation of the electric fan harness and complete the cooling system re-do.

The wiring went in pretty well. I was able to tie into the original fuse box in the car to allow picking up the wiring which was electrified when the key was on and the wiring that was on all the time. I also was able to use some of the original holes in the car to mount the relay. I finished the wiring install by wrapping the harness exactly as the stock harness was wrapped, so the whole setup looks like it belongs there.

 

 

 

I thoroughly tested the system after installation and everything went really well. I installed a 180 degree thermostat and the system performs perfectly. It cycles exactly as expected and the car runs at a perfect temperature all the time. It also handled the 100 plus degree summer in Memphis with no issues.

 

Cooling System Refurb Continued

So where I left off with the Cooling System, my radiator was at the radiator shop being boiled out and soldered up where it had a leak.

Unfortunately, I got a call from the shop and they asked me to come in. When I got there, they had the radiator off to the side. Boiled out, but obviously not soldered up. They basically told me that it had a header leak, and because it was a 40 year old radiator, they would not solder it up. They offered to re-core it for $400, but a new rad is only $260, so I said no thanks and went on my way.

When I got home, I had to figure out how to seal the radiator. I had read that using a vacuum to pull the epoxy into the joint would make the repair much stronger. Talking with a buddy who works on vintage Volvos confirmed that this repair could work.

With all that in my mind, I pulled out the automated vacuum pump I built a few years ago for building composite airplane parts. I sealed up the radiator and then hooked up the pump system and pulled a vacuum. I could hear the leak 'sucking'.

I worked up a batch of JBWeld and spread it around the leaking area. I could actually hear the epoxy being pulled into the leak and then there was silence! After letting the epoxy cure overnight, I pulled a vacuum against the radiator and it held for several minutes. Definitely a successful repair.

Next up, I needed to install the fan on the radiator. I used some self tapping screws to mount the fan to the outer edges of the radiator shroud. This is a definite measure twice, drill once type of job....

With the fan mounted to the radiator, it was time to install the whole assembly back in the car. The fan motor did not clear the frame crossmember. I elongated the holes in the radiator braces to get the fan motor off the crossmember, but will eventually make new longer braces to pull it completely off the crossmember.

To be continued......