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Old 08-20-2021, 11:45 AM   #1
tmp042
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Default Home made/designed radiator

After purchasing a new Mishimoto radiator and unboxing it, I was rather disappointed with the build quality and poor welds. I looked at other local brands, but they too were similar in construction.
I then decided to try and build my own (never made one before). Its taken many months, but finally tonight the last piece was completed and its ready to be dropped off to the welder.
The fan mounts were 3D printed and the inlet dome end was cnc machined. Filler neck is made by speed-flow and I machined up a sleeve to match the oem overflow hose which was pressed over with a dab of loctite.

I really like the Fumoto drain valve on my oil sump, so decided to put one on the bottom end tank to make it easy to drain the coolant. Most aftermarket radiators just expect you to cover your arms in coolant when loosening the drain bung.
I drew the end tanks in CAD and then had them laser cut from 5005 and precisely cnc folded (the entire top tank is a single piece).

All the other fittings I machined from 6061 based exactly on the factory dimensions. The new radiator is still the same size as oem, but with a thicker 38mm core (its still 50mm thick which is the same width as the plastic end tank crimping). Fitment in the engine bay is perfect and absolutely no interference with the hoses or aftermarket SSI headers.



















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Last edited by tmp042; 10-01-2021 at 10:22 PM.
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Old 08-20-2021, 09:40 PM   #2
tmp042
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To confirm fitment I first mocked everything up from laser cut MDF and 3D printed the fittings. Lucky, as I did indeed make a whoopsie.
I find the kitchen bench is usually the best level place to work.. once everyone has gone to bed





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Old 08-20-2021, 09:51 PM   #3
murrdogg24
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nice work, sometimes you just gotta do things yourself
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Old 08-20-2021, 10:04 PM   #4
tmp042
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Unfortunately with this build I’m finding that a lot. Many aftermarket products don’t fit correctly and need to be modified. Sadly when contacting the manufacturer they don’t seem at all surprised and simply refund or replace. I would be horrified if one of my products had a defect.
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Old 09-30-2021, 08:30 PM   #5
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This thing is beautiful.
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Old 09-30-2021, 08:54 PM   #6
tmp042
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Cheers, since posting this it was immediately dropped off at the welder the following day. Unfortunately he has a huge work load and I’m still waiting for it to be glued together.
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Old 10-01-2021, 06:53 AM   #7
KillerBMotorsport
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That looks great! Whos core did you go with?

We use an industrial style drain valve on our radiators. I don't see why the Fumoto won't work, it's just more expansive and takes more space; I could see it being too big to use on a GD chassis if the OEM subframe is still in use.

Looking forward to your next updates.
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Old 10-01-2021, 08:30 AM   #8
BlueSTI4Me
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Looks legit and awaiting finished images.
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Old 10-02-2021, 03:13 AM   #9
tmp042
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Quote:
Originally Posted by KillerBMotorsport View Post
We use an industrial style drain valve on our radiators. I don't see why the Fumoto won't work, it's just more expansive and takes more space; I could see it being too big to use on a GD chassis if the OEM subframe is still in use.
I’ve never heard a weld on bung and bolt being called that before (industrial style drain).
The core is locally produced in a relatively unheard of place known as Australia (some even dismiss its existence as fake news), though its not designed on any catch phrase technology. It uses an extruded tube with a 1.6mm “heel and toe” (for longevity and strength).
Luckily I don’t have a GD so Fumoto fitment is not an issue.
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Old 12-23-2021, 04:33 PM   #10
tmp042
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Finally got it all welded up and pressure tested. Next step to get the end tanks powder coated satin black.
Some figures comparing it to oem.

Custom Radiator (ADRAD core)
36mm thick core
84 tubes
6.2kg

Oem Radiator
26mm thick core
76 tubes
3.3kg

I made it exactly the same overall dimensions as stock, though has more tubes and they are wider.


Last edited by tmp042; 12-23-2021 at 05:59 PM.
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Old 12-23-2021, 06:23 PM   #11
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Old 12-23-2021, 07:25 PM   #12
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Old 12-23-2021, 07:36 PM   #13
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Looks excellent!
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Old 01-12-2022, 10:36 PM   #14
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Holy cow that is beautiful. Keep up the good work. Better yet, draw up all the dimensions and specs and work with someone like KillerB or Grimmspeed to put it in production.
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Old 01-12-2022, 10:48 PM   #15
tmp042
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Cheers. I initially had a lot of interest but using a high quality core drives the price up and peoples mindset these days is “Why, when I can buy four chinesium ebay ones for that price”.
Killer B uses F1 technology in their radiators, so I can’t compete with that level
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Old 01-02-2023, 10:45 AM   #16
tmp042
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The dome was cnc machined by a ex work colleague on his own lathe which I then hand cut and used emery paper to hand lap until it was perfect. I wanted the radiator to mimic as close as possible to the oem plastic end tanks.







And yes, it is presented better than what is currently available

"just important that it's not presented as better than what is currently available"

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Old 01-02-2023, 10:59 AM   #17
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Quote:
Originally Posted by speedyHAM View Post
Holy cow that is beautiful. Keep up the good work. Better yet, draw up all the dimensions and specs and work with someone like KillerB or Grimmspeed to put it in production.
Kb already sells a rad with an F1 core.



Quote:
Originally Posted by tmp042 View Post
And yes, it is presented better than what is currently available
may want to test out that theory before making claims
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Old 01-06-2023, 06:46 AM   #18
tmp042
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Kellen, one day you too can hopefully find satisfaction in “built, not bought”.
It’s very rewarding and you know quality control is 100%
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Old 01-06-2023, 08:47 AM   #19
K3rm1tth3fr0g
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This is an exorbitant level of beating around the bush to make up for the lack of meaningful testing and validation for your projects...

"100% quality control" is coming from the guy praising off the shelf headers he had to chop and weld in order to make fit

That's called using crap parts and working around them.

Why didn't you just weld your headers from scratch? Smh, not very 'built, not bought' of you.

Quote:
Originally Posted by tmp042 View Post
It's very rewarding and you know quality control is 100%
Guess ya didn't check out the threads

Everything need not be custom simply for the sake of it. But there's definitely some custom bits here and there though, not to mention everything that was reconditioned and rebuilt

Last edited by K3rm1tth3fr0g; 01-06-2023 at 11:23 AM.
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