So, it isn’t pretty but I think it’s gonna hold. When I shopped my 2011 LX570 I was aware of the radiator issue and asked my PPI inspector to make sure they took a look. There are no leaks, but what was not noticed (can’t fault them for it) is a tiny hairline crack in the usual place. Honestly if one did not know what these can grow to, you wouldn’t even notice it.
It is not leaking now but I don’t want to fall victim to a failed radiator as I JUST went through that with the car I got rid of to get the LX (a 2004 Volvo XC70 with 127k mi on the clock).
So I did some research, I found some have had success patching but usually only temporarily. Many go to JB Weld or another form of epoxy or putty with mixed results.
The qualifications were an epoxy adhesive that can withstand prolonged high temperatures (radiators run 212+F) AND adhear to glass filled nylon plastic (the material of the tank). Many epoxies do NOT stick to many plastics or they don’t meet the temp requirement (many maxing out at 150F).
Then I came across the VersaChem Radiator and Tank repair kit. It includes a black epoxy resin, a sheet of fiberglass fabric, sand paper and a brush. I read a lot of online reviews and learned that this epoxy sets up FAST! Much faster than the 5min they claim. Cold temps slow the process and I lucked out as it has been in the upper 20’sF here this week and bought me more time.
So I set out to reinforce the area that fails in this radiator so it does not! Remember I do not have a leak yet so no coolant contamination to worry about. With the radiator cold I removed the cap to release any internal pressure before working. I masked off the area of the hairline crack +1” and sanded it well to give the epoxy something to grab on to. Then I cleaned the area with mineral spirits and let dry. I cut the fiberglass to cover the area. The fiberglass is key as this is what will provide the ridigity of the patch. Then I mixed the epoxy in its pouch and worked it together quickly. It generates a LOT of heat when activated so I wore double layer of latex free gloves when working it. Then working quickly I put down a moderate layer over the area I sanded (both on the smooth area of the tank top AND up and over the top of the rectangular boss in the tank where the part numbers are printed). I then quickly lay in the fiberglass and while holding a corner down I covered it with more epoxy and started to brush and dab at it to saturate it with epoxy and get out any air bubbles and make sure it kept the contours of where the boss protrudes from the tank. I kept working it until the epoxy really started to set, about 2-3 min. I made sure the fabric was covered and added enough in the layer of epoxy on top that you really cannot even see the fiberglass. As it became firm and only tacky I continued to work it flat and into the boss crease with my fingers until it was fully hardened.
I now have a very ugly but stout black patch about 1 1/2” wide by 4 1/2” long across the top center of my radiator. It is hard as rock. I replaced the plastic shrouds over the radiator (it is a fluffy LX after all) and let it sit over night. The destructions claim that it works fine below freezing (32F), I found the activator was getting pretty thick until I mixed the two and it started to generate heat. They also say 20min to full strength (can be done on the side of the road in a pinch).
I feel confident that I have bought myself another 100k mi out of this radiator (at 101k mi now). Either by reinforcing the area so the hairline crack does not open any further OR by sealing in any crack that may still form in the future.
Hopefully I will not need to eat my words in a year or two.
Here is the product, it gets great reviews from those that are able to work it quickly before the epoxy sets and bad reviews that end up with a half finished job and an applicator brush stuck to their mixing cup. Read the directions twice, prepare and move fast. You have been warned.
Versachem 90214 Plastic Tank and Radiator Repair Kit - 30 Grams
https://www.amazon.com/dp/B0009MZI4M/ref=cm_sw_r_cp_api_OGGCAbKTNE3B8
Oh, and like an idiot I didn’t think to take a picture until I placed all the covers back on. So next time I check it or the battery etc. I’ll snap a photo.
