How To - fix your radiator the WRONG way.

Hey all - not sure anyone would find this helpful but here's how I fixed the radiator in my '01 AC.

Took the truck out on the Thursday before Memorial Day and saw that the lower tank O ring had clearly failed and was leaking coolant. I think the radiator was about 13 years old, so not unexpected, but not great timing.

The PROBLEM: I have a flight out Tuesday and could get stuck in traffic.
The GOOD: Rockauto has Denso in stock and local so they can UPS it for Friday!
The BAD: In typical UPS fashion, they have to test the packaging so the box arrived with a small hole in it. But, I had it on Friday evening.

Saturday, I opened the box. It looks like UPS is now using AI to target weak point in packages as the one hole in the box snapped off the overflow connection. I don't have time to wait for another radiator. Installed and epoxied the overflow tube on. Rockauto offered a partial refund to cover a repair.

Of course it didn't work, so I looked at options. The Dorman repair kit had several bad reviews. I ordered a M8 to 10MM barb (they didn't have the 6mm in stock, but that may have worked). Home Depot only had thread to barb, not barb to barb - so I bought 3/8 - M to F - 3/16. I had the clamps and hose. Drilled out the overflow hole and threaded / epoxied the fitting in. I did let it cure for 24 hours to give it the best chance to hold.

Yes, that is a pex clamp - I used one on my old pathfinder when the transmission line clamp rusted away and it outlasted the car.

It made a trip after the repair, so I'll consider it a permanently fixed. Until it breaks.