While replacing the top rad hose I broke the plastic nipple off and think there is a solution without replacing the whole radiator. Items needed:

1. Fuel line check valve similar to the one pictured here:
One Way Check Valve for 1/4 Fuel Line

2. Marine 2 part epoxy.

3. Two small screws.

4. Small hose clamp.

Procedure:

Used a paperclip to remove the rubber check valve then flushed it several times to ensure all debris was removed.

Cut one male end in half for a snug fit into the broken nipple.

Drilled two small holes at the 9 and 3 o'clock position at the center junction of the check valve.

After inserting the check valve into the radiator use two small screws to attach the check valve to the plastic protruding ridge.

Attach the other end of the check valve to the hose with a new strong clamp.

Knead a small amount of the marine 2 part epoxy and use it around the connection between the broken nipple to the check valve.

Replace top cover.

I did this over 6 weeks ago and have driven over 1,500 miles in summer heat without any leaks or problems. It all cost less than $30 and took about a half hour. If anyone has tried this and encountered problems please speak up. Obviously this is an experiment on my part so repeat at your own risk. Thanks!

 

Others have done similar with a nylon threaded to hose b-a-r-b adapter. The place you are going into does not have much meat, and the plastic rad sections are subject to considerable expansion. Holding until payday is good, you have exceed that. Pix of the inside of the plastic area, that crack is where the screw fits in (and leaks).

 

Thanks for the pic. When I put the screws into the protruding edges I was careful not to breech the inside of the plastic containment due to the heat expansion. The previous owner already switched from orange to green coolant and I added water wetter.

I had read about the nylon threaded approach but did not try that due to the expansion and it was blind luck the check valve I bought was a perfect airtight fit without needing to thread anything. I used the 2 part marine epoxy because it seemed to be a low risk addition. I used to be a crew chief on Cobras in the Army and as most can attest to, that is not a situation overflowing with parts out in the field so we often had to work with what we had.

If this doesn't hold I will get the new rad. Thanks again!

 

I hate to pop your bubble,what you have done may be a short term fix but that is all.
With our radiators, the first problem to show up is a partial restriction which can not be resolved. Second issue, the plastic tanks become brittle and fail, in your case the nipple broke off.
There is no such thing as a permanent fix for this, no matter what you try, either the repair will fail and or the plastic will become more brittle and you will loose a radiator, possibly a head gasket and or drop a sleeve, none of which makes repairing a broken nipple worth while.
Go buy a new one along with a 180 t/stat and new coolant pressure cap and save yourself an engine job.

 

New Nissens radiator is about $230 from Rockauto.com
I went that route.
No problems since as I won the trifecta.

replaced

radiator

fan clutch with new Hayden HD

thermostat with new Rover - 180 degree. Not a Motorad.

And - thankfully no problems since January 2013

 

Thanks and I have seen others reference the Nissens and 180 T stat. Glad it has all been working for you.

 

Ive used this forum quite a bit to do repairs since I got it last year and I did not intend to misrepresent this repair as I had no illusions about it being long term. It was simply another option for those needing a temp fix and more importantly, there is no such thing as a long term repair on a Rover or any other vehicle.

I have been keeping a close eye on everything and it appears you are saying that this could go from zero to new head gasket without warning. Wouldn't there be at least one or two symptoms? Im not asking to avoid replacing the rad but only for information. This forum and your posts in particular have been extremely helpful. Thank you.

 

Not worth the risk.
You have one coolant loss event - and depending where you are
and how busy you are at the moment - distracted or such

Engine overheats and drops a liner. Game over.

I would order the Nissens now and put in a new 180 degree.

Imagine - peace of mind.
A normal vehicle.
Finally.

 

Thanks and that makes sense....except for the last part. Peace of mind and normal cannot be used in the same sentence of owning a D2. (It is my favorite vehicle and love it not to mention the deal I got on it with craigslist)

 

You want to bet. If you keep you vehicle ahead of it's service requirements, using good quality parts, the odds are with you that your truck will run well and if it does have an issue, the cost can be a lot less.