Hey guys,

Was installing my new radiator this afternoon after work and the very last thing I had to do went wrong. I got a bit heavy handed trying to unbolt the overflow nipple to replace it with a stopper and the soft alu just snapped and now a piece of it is still left in the rad, as pictured.


What should be my plan of attack here? Would easy out screw extractors be of help to grab it out if I was careful?

Thanks in advance for help.

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A pair of long nose pliers pushed into the hole could also do this if you don't have the extractors.

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Ah okay, I might actually give this a go before I set off to buy extractors.

Thanks for the tip

Once you have fished it out, you will need to take it to someone good at welding aluminium. There is a place in Malaga that does ok.

Similar to you, I put a crack in mine when I had one, I don't think it cost much to fix.

I'm not sure what will need to be welded? There's a thread where that piece is stuck, and once that is out I can screw in the bolt with a rubber o-ring that was supplied with the radiator.

Everything looks intact aside from the piece that is stuck in there.

If there is one thing I've learned, it's to be gentle with nipples.
Ezy out should fix that.

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Is the piece inside the radiator floating loose or still screwed to the threaded section? Too hard to make out from your pic.

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Bye bye betty blue. Hello F6.

Still screwed to the threaded section, it's not just sitting in there.

Proceed with ezy out - extreme caution applies. Good luck.

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Bye bye betty blue. Hello F6.

Thanks again for the input guys, all went well in the end. Carefully tapped in the extractor with little effort as the metal is so soft and slowly got it out. Car is back up and running!

I'll have to start joining in on club cruises and stuff soon.

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