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How to repair aluminum radiator

Aluminum is used in a wide variety of applications. Some of them are the construction industry, where you find it in doors, windows and siding; the transportation industry, where it is found in automobiles, trucks, bicycles and ATVs; in the consumer goods industry which covers everything from toys to electronics; and in many industrial applications. Repairing aluminum is fairly simple in most cases. The article below touches on some methods but it is by no means a complete guide to repairing aluminum.
Method 1 of 5: Repairing Aluminum with High Temp Metal Sealer
1.       Use this technique for repairing aluminum radiators and other engine parts. It can withstand temperatures of 2500 degrees Fahrenheit (1371 degrees Celsius).
2.       Clean the aluminum piece thoroughly, removing any paint, grease or oil on the surface. Sand lightly and wipe off any particles left by the sanding.
3.       Apply a thin layer, no more than 1/4 inch (0.6 cm), of a high-temp metal sealer into the crack or hole using a putty knife, trowel, spatula or spreader.
4.       Allow to dry for 24 hours and then heat cure by baking at 425 degrees Fahrenheit (218.3 degrees Celsius) for 1 hour.
5.       Continue adding layers, allowing drying time and heat curing time, until the cavity is filled.
6.       Sand out any unevenness and apply a powder-coat paint if desired.
Method 2 of 5: Repairing Aluminum with Minimal Tools
1.       Repair small indentations and dents by applying pressure to the dent from the rear. You can use your fingers or a block of wood, depending on the thickness of the aluminum and if it is mixed with another metal.
Method 3 of 5: Repairing Aluminum with Aluminum Putty
1.       Fix holes or cracks in aluminum by using a putty knife or other spreader to fill in the area with aluminum putty. Smooth it as much as possible and allow to dry.
2.       Sand if necessary and touch up the repair area with aluminum paint tinted to match the rest of the piece.
Method 4 of 5: Repairing Aluminum by Brazing and/or Welding
3.       Clean the aluminum piece thoroughly, making sure it is as clean as possible.
4.       Flatten the work area by filing or hammering out small dents and protrusions or filling them in with aluminum putty.
5.       Don safety gear, eye protection, work gloves and welding helmet to provide face protection. You should also wear heavy duty pants such as denim or cover yourself with a welding apron.
6.       Follow the brazing or welding equipment manufacturer's directions for using the equipment. There are different techniques for different situations as well as infinite variables in flux and brazing rods.
7.       When brazing, do not direct heat onto the joint itself. Brazing works by capillary action, and as such even heat must be applied to the area surrounding the joint to allow brazing alloy to become molten and be drawn into the joint itself.
8.       Consult a professional if you are unsure about what to use for a particular repair.
Method 5 of 5: Repairing aluminum by Patching
1.       Use patching to repair aluminum boats, hence the name.
2.       Purchase a can or tube of aluminum boat patch. Do not buy more of the patch than you will use at one time. Once the container is open, it will set up within hours, even if the container is resealed.
3.        Clean the area to be repaired thoroughly, removing any grease, dirt or oil. Sand the area to give the patch something to grip on to. Sand the area to give the patch something to grip on to.
4.       Heat the area around the hole or crack with a propane torch until the solid boat patch will wipe on easily. Allow to dry cure and paint if desired.

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