Plastic radiator broken on F650

[biker baz]

Can anybody help with advice on gluing a bit on the side (no pun) of the radiator at the rear where the return hose attaches to the main unit.
After getting a price to replace it & a free heart attack, then scanning Trade Me & Ebay to no avail I moved to Plan A.
This part is a composite plastic that has fibreglass mixed in so plan A to plastic weld it was flagged.
Plan B was to fabricate a new side piece which was flagged by the radiator specialist.
Plan C was to glue +/or attach it. Lots of glues were excluded because of low temperature (250F;200C) or pressure resistance, or not waterproof.
The best option looked like Knead it, with 120C continuous but that didn't go well.:( It may be the type of plastic, the surface was not roughed up enough, or my mixing of the epoxy.
Another try with a new tube might work, or devcon plastic welder, or a fibreglass repair kit, or selleys plastics glue which is water resistant only & would need some reinforcing.
Any suggestions are welcome.
Cheers

[CookMySock]

Even high-temperature epoxy wont like that. If you do use epoxy, you might post-cure it - raise the repaired items' temperature until the epoxy only just begins to soften, and allow to cool and reharden. Continue to repeat this process and the epoxy will raise this "soft" point higher and higher.

On a long trip, I wouldn't be able to get it out of my mind. I don't futz with cooling systems - I always repair them properly. :nono:

[bsasuper]

Do you mean the pipe fitting has snaped off? If so a metal pipe fitting can be screwed into the hole, If not, I have used quick steel with good results,it can take 260c, supercheap stock it.Its a lot stronger than the stuff selleys make.

[AllanB]

Sorry, but all the fixes sound very temporary and ultimately you'll need to replace it.

Jump on the net for MBW forums and see if you can find a overseas supplier of BMW parts as they are bound to be a lot cheaper than the NZ list price. For example some Honda parts are 6 times cheaper ex USA - for the same exact factory part!

Alternatives may be to see if a local radiator maker can whip up a alloy replacement box for the plastic piece. Or there are much cheaper aftermarket radiators that may possibly be adapted.

[CookMySock]

Alternatives may be to see if a local radiator maker can whip up a alloy replacement box for the plastic piece. Or there are much cheaper aftermarket radiators that may possibly be adapted.Yep. I think you will be surprised how cheap it is to get a full custom alloy one made.

If you are near a hyosung 650, see if it is in the ballpark - these are about $240 new incl freight. Search on this page
http://www.hyosungsource.com

[bsasuper]

A quick look on ebay, one for nz$110+ shipping from england, one for nz$200+shipping from the states.Whats a new one worth?
I wanted a small radiator made to act as a heater, was quoted $700, where are these cheap custom made ones?

[hayd3n]

it most likely can be plastic welded!!
uits glass filled nylon
ive fixed a couple of radiators iust like that

[biker baz]

Thanks for the advice y'all.
The good news is on the off chance I showed the radiator to the plastic welder who was welding some panels (as they do) & he confirmed the suggestion of Hayd3n that nylon & glass fibre were the materials. PA66GF30 is stamped on it as ID. So good call.
The test will be if it stays together after the xpansion & contraction of normal use.
It is tempting to spend up on some plastic protector bars for side impacts to the side of the radiator.
Cheers

[gammaguy]

im speaking from years of experience with a rental fleet here.dont mess around trying to repair it,it wont work,and a boiled engine is a very real and very expensive possibility

take your original to A1 Radiators in Christchurch and they will make you a new one.

Failing that,a used one is very easy to find in these parts,let me know if you get stuck.

[budda]

If you REALLY want to repair, rather than replace it, send it to Auto Radiators in Invercargill - Frank there is an absolute Magician, seen him fix things that were literally skip-material ....... if its fixable, Frank is your man - but if he tells you its rooted, dont second guess him - throw it away

[MSTRS]

Any experience I have had with plastic radiators and 'repairs' has not had a happy outcome.
Unless the exact same plastic is used for the repair, and the new/old are totally melted together it will fail.
A difference in the plastic compound, or any glue used, will behave differently as the temperature on the system rises, which just leads to splits etc opening up again.

[hayd3n]

Any experience I have had with plastic radiators and 'repairs' has not had a happy outcome.
Unless the exact same plastic is used for the repair, and the new/old are totally melted together it will fail.
A difference in the plastic compound, or any glue used, will behave differently as the temperature on the system rises, which just leads to splits etc opening up again.

thats why i assume he got it plastic welded with nylon welding rods