Maya Ellison
A cracked plastic radiator can be a headache, but there are temporary fixes to seal the crack and get your car running again. While some suggest that the only reliable solution is to replace the radiator, this can be costly, and sometimes a quick fix is needed to get you home or to a shop. One common method is to use an epoxy resin, such as JB Weld, to fill in the crack. This method has worked for some, but it is important to note that it may not hold forever and could fail within a day or lead to cracks elsewhere. Other temporary solutions include using Flex Tape, Gorilla Tape, or plastic welding. For a more permanent solution, it is recommended to replace the radiator or the plastic tank at the top, which can be done at a radiator shop or by buying a kit to fix cracks in plastic parts.
How to seal a cracked plastic radiator
| Characteristics | Values |
|---|---|
| Temporary fixes | JB weld, epoxy, plastic welding, Flex Tape, Gorilla Tape, fiberglass repair kit, soldering iron and plastic zip ties, water weld, RTV, superglue, fiberglass cloth, Devcon epoxy, plastic weld |
| Permanent fixes | Buying a new radiator, contacting a radiator shop for replacement, buying an aluminum radiator |
| Cost of buying a new radiator | $150-$300 |
| Cost of replacement by a radiator shop | $500-$600 |
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What You'll Learn
Sand the area to prepare for repair
Sanding the area around the crack in your plastic radiator is an important step in preparing for repair. This process helps to create a rough surface, improving the adhesion of the repair material.
First, you'll need to clean the area around the crack. This ensures that any dirt, grease, or debris is removed, creating a clean surface for the repair. Use a mild detergent or soap and water to gently clean the area, then dry it thoroughly.
Once the area is clean and dry, you can begin sanding. Use a fine-grit sandpaper, such as 120- or 220-grit, to lightly sand the area around the crack. Sand in a circular motion, ensuring you cover the entire area where the repair material will be applied. This process will help create a slightly rough texture, improving the bond between the repair material and the plastic radiator.
It is important to note that you should not sand too aggressively or use a very coarse sandpaper, as this may damage the plastic further. Be gentle and focus on creating a uniform texture across the repair area.
After sanding, it is a good idea to clean the area again to remove any plastic dust or debris created during the sanding process. Use a soft, dry cloth to wipe the area, ensuring it is free of any residue before proceeding with the repair.
By properly sanding and preparing the area, you will improve the chances of a successful repair and create a strong bond between the repair material and the plastic radiator.
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Use JB Weld or epoxy for a temporary fix
JB Weld or epoxy can be used to temporarily fix a cracked plastic radiator. This method is ideal if you need a quick fix and don't want to spend a lot of money.
To use JB Weld, start by cleaning and drying the cracked area. Rough up the surface around the crack with sandpaper to help the weld adhere better. You can then apply the JB Weld in two layers, allowing each layer to dry before applying the next. This method has been known to work for a long time, with one user reporting that it held for well over a year before eventually starting to seep again.
Another option is to use a combination of JB Weld and fiberglass drywall repair mesh. Scuff up the repair area and clean the plastic thoroughly before applying the JB Weld and mesh in layers. This method has also proven effective, with one user reporting that it held for a long time before their friend started experiencing new cracks in the radiator.
While JB Weld and epoxy can be effective temporary fixes, they are not permanent solutions. The constant pressure and de-pressure cycles that radiators experience can cause cracks to form elsewhere, even after a successful weld. Therefore, it is recommended to replace the radiator as soon as possible to avoid potential engine issues.
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Drill small holes at the end of each crack
If you're looking to repair a cracked plastic radiator, one method is to drill small holes at the end of each crack to prevent them from spreading further. This can be done using a drill bit, with the size depending on the crack but typically ranging from 1/8th of an inch to 1/4 of an inch. It's important not to go too big, as the goal is simply to stop the crack from lengthening.
After drilling, it's crucial to sand the area around the holes to ensure a smooth surface for the application of the repair kit. You can purchase a kit designed for fixing cracks and holes in plastic car parts, which typically includes a fiberglass cloth, sandpaper, a metal tube, a brush, and a two-part epoxy. The epoxy will need to be mixed, and once activated, you'll have a limited time before it starts to harden, so work quickly.
Spread the fiberglass cloth over the cracked area, covering it with epoxy. The epoxy will start to heat up and may become difficult to handle, but this indicates that it's starting to work. Within 30 seconds, it will begin to harden, so be prepared to move fast. It's recommended to leave it overnight to ensure it's completely dry.
While this method can be effective for a temporary fix, it's important to note that the underlying issue of the radiator's age and brittleness remains. As such, a more permanent solution is to replace the radiator or its end tanks, which can be done at a radiator shop or even by yourself with some automotive know-how.
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Apply fibreglass cloth and epoxy
While some sources suggest that the only reliable way to repair a cracked plastic radiator is through plastic welding, others have had success using a combination of fibreglass cloth and epoxy. Here is a step-by-step guide on how to apply fibreglass cloth and epoxy to seal a cracked plastic radiator:
Prepare the radiator
Before applying any epoxy or fibreglass cloth, it is important to prepare the radiator. Start by draining the coolant system. Then, use a utility knife to scrape away any excess dirt, grease, or debris from the cracked area. Wipe the area clean with a cloth or rag, ensuring no paper towels are used as they may leave traces of fibres behind.
Sand the radiator
Once the area is clean, use sandpaper to sand the area around the crack. This will create a rough surface for the epoxy and fibreglass cloth to adhere to. It is important to sand thoroughly and get down to the bare plastic. After sanding, be sure to wipe away any dust or debris with a clean cloth.
Drill small holes
To prevent the crack from spreading, drill small holes at each end of the crack. The size of the drill bit will depend on the size of the crack, but it is recommended to use a small bit, such as 1/8th of an inch, to ensure the hole is not too big. Once the holes are drilled, sand the area around the holes again to ensure a smooth surface for the fibreglass to stick to.
Mix the epoxy
Open the epoxy by squeezing both ends to break the centre seal. Then, mix the two parts of the epoxy together for about 30 seconds. It is important to work quickly as once the epoxy starts to interact, you will have less than 5 minutes before it starts to harden.
Apply the epoxy and fibreglass cloth
Using the supplied brush, apply the epoxy to the surface of the cracked area and around it. Then, spread the fibreglass cloth over the crack, ensuring it overlaps the epoxy-covered area. Cover the cloth with more epoxy, fully saturating it.
Allow the epoxy to cure
The epoxy will start to heat up and harden within a few minutes. It is important to allow it to cure completely before using the radiator. The curing time may vary depending on the product used, so be sure to follow the manufacturer's instructions.
It is important to note that while this method may provide a temporary fix, it is not a permanent solution. The constant pressure and temperature cycles that a radiator undergoes can cause cracks to reappear or form in other areas. Therefore, it is recommended to regularly check the radiator for any leaks or cracks and consider replacing it if issues persist.
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Replace the radiator
If you are not confident in your ability to repair a cracked plastic radiator, or you are concerned about the long-term durability of a repair, you may want to consider replacing the radiator altogether.
While repairing a cracked plastic radiator can save you money compared to replacing it, the repair may not last long due to the constant pressure and de-pressure cycles that the radiator undergoes. This can cause new cracks to form, requiring further repairs or replacement.
Radiators are far cheaper now than in the past, especially when purchased online. When replacing a radiator, it is important to consider the condition of the core. If it is old and full of scale and buildup, it is better to replace it with a new one.
Additionally, if you are repairing the radiator while it is still in the car, it is important to drain the antifreeze until the level is below the crack line to prevent the antifreeze from seeping out and ruining the repair. This extra step can add time and complexity to the repair process.
By choosing to replace the radiator instead of repairing it, you can avoid the hassle and uncertainty associated with repairing a cracked plastic radiator and ensure a more permanent solution.
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Frequently asked questions
You can use a temporary fix like JB Weld, epoxy, or plastic welding, but the best option is to replace the radiator.
There is no single best epoxy, but some products that can be used include JB Weld, Devcon epoxy, and Gorilla Tape.
Clean and sand the area, then apply the epoxy in smooth, even coats, allowing each coat to dry before applying the next.
