I have a 95 D1 and am planning on fixing my radiator this weekend.
I have a brazing (sp?) torch and brazing rods. Have never done
this before but cannot see spending the money to have someone do
it when I am perfectly capable. I can see the leak is coming from
the fan switch bung.

Question I have:
Any advice on doing this from someone who has done it themselves?

I am sure the radiator is good otherwise as it cools wonderfully.

 

I cannot say I have done this, but i will say i give you props for wanting to braze it first before either replacing or having someone else do it. i am a union ironworker/welder by trade and have a nice exhaust leak in one of my catylitic converters that i would like to try to braze before i have to replace it... i would say just watch the heat, dont over do it with the torch on that radiator, and be very sure that the metal you are brazing to is nice and clean.

 

Got a wire wheel type attachment for my die grinder to clean off the old paint.

If I am seeing correctly I believe these radiators are brass?

I will take pictures and post them up for anyone elses future reference.

 

I've brazed series Rover radiators without a problem, so I can't think of any issues, aside from, as mentioned, making sure it's all clean. And obviously, do it in a well ventilated area.
Oh, and yeah, they are brass, that's one reason it's easy to get them re-cored.
If you're feeling adventurous you could drill a hole in the bottom left corner and braze in a drain ****. I had them do that to mine when I had it re-cored. Makes draining the radiator not messy at all.

 

DO NOT braze the radiator!!!! If the leak is comming from the fan switch bung use soft solder 60/40 is fine. Dont let the heat transfer to the seam of the tank,its soft soldered too. If you have a crack in the tank itself use silver solder. Clean everything before you turn the tourch on, Work fast, use cooling water if needed. Brazing will cause the tank to become very brittle, Dont braze radiators!!!!!!

 

I was talking to one of my fellow techs here at Audi and he said the same thing.
Mentioned acid core solder to clean contaminates while soldering.

 

Yikes!!! Man, don't know what I was thinking... one of those days I guess. Sorry!
Yes, solder. I've also soldered new bungs in the series fuel tanks too.

 

If you can find a friendly radiator shop,they might sell you some soldering paste. The paste is made to "tin" the surface at a low temp. Solid solder works best for what your doing. Clean it, tin it, then solder.. Youll be surprised how little solder it takes to make a good repair if its clean first.

 

My fellow tech has some paste from when he worked at a independent shop he is going to give me. Also offered help which I believe I will take him up on. Thanks for your help guys. Again the reason I joined this forum. I know a ton about VW and
Audi but nada about Rovers. I will post pics and updates as I complete the project.