[Richard]

I have not had good results with replacing my radiator. I replaced it in 2017 with one obtained from the original supplier. It lasted two years before leaking slightly at the tube header interface. I replaced that one with a core obtained from Rocore. It lasted three years before developing a similar leak at the tube header interface. 

I spoke with the original supplier who was not interested in making a heavier duty core for concerns over cooling efficiency. 

Long sigh. The engineer’s definition of insanity is doing the same thing over and over but expecting a different outcome the next time. The original supplier pointed me in the direction of Thermal Solutions. On their website I found they manufacture a heavy duty core where the tubes are tig welded to the header place instead of the conventional soldering. Like all the core manufacturers they do not sell directly to the public, so I asked them to give me some names of outfits within driving distance who they dealt with. I used Complete Radiator in Orlando, and was absolutely thrilled with their knowledge, service, and pricing. 

I went with Thermal Solutions UltraFuse design https://www.thermalsolutionsmfg.com/wp-c...uty-05.pdf. There are some things of note that I do NOT have real world data on. Obviously, I do not know if this will end up being a more robust solution. Second, the UltraFuse core used less rows of tubes, five instead of six, in the original, but the tubes are 5/8 wide instead of 1/2. And then the fins are V fins in the UltraFuse as opposed to straight fins in the original. I was assured by the radiator folks the UltraFuse design had MORE cooling capacity than the original but that real world data will have wait until the first hot day mountain climb to know for sure. Test drives in flatland Florida on a 90 OAT day did not result in any fan activation, and the engine temp stayed right at the tstat opening temp 196. That is the same result I would have seen with the original design. 

The removal was aided by none other than Bikestuff, and the install by another guru Russ White. Two things are supercritical when removing or installing. One, a work surface such as a lift table to help get the mechanic in and out of the “hole”. And more importantly, a helper to hand items to mechanic in the “hole”. It takes my decrepit bones a good five minutes to wriggle in or out of the confined space. So Mucho Gracias to Bill and Russ. 

I will report back on the longevity as I accumulate miles and hopefully years. I will also report back on cooling performance after a mountain workout.

======================================================================= I want to update this post with real world experience. We have had the opportunity to climb some 6 to 8 % grades in 95 degree temps on the 2024 tour. The core from Thermalsolutions discussed above is cooling just fine. Fan comes on at 204 and drops to 197 in seconds.