Need ideas for making a coolant cross over tube.

[Iceman0502]

I'm in the process of doing a motor swap in my wagoneer and need to discuss lower cross over tube ideas. The radiator has the lower port on the drivers side however the motor has the inlet on the passenger side. It will need two bends installed on each side to go around a few obstacles.

I know it would be best to get a different radiator especially one for a chevy motor, but I plan on using the truck for daily driving and want to be able to fix it any where on the road. Also I personally do not own a welder for aluminum.

The amount of rubber hose should be keep to a minimum to so it is only required to change a small hose, rather than trying to find a 30" length of hose at a local store

Some options that were considered but there are concerns.

Copper - solder each connection and braze on some metal tabs to make mounts so it is secured.
pros - Easy to buy the pieces at the hardware store and I can use fittings to get the perfect angle that I need with minimum flow restrictions.
cons - Will the joints eventually crack from the vibration of the motor and the road?

Aluminum tube - Have my friend weld it and hopefully get some nice bends
pros - Nice to work with if you can do the work
Cons - doesnt aluminum and copper radiators react with one another. i would have to add a pice of zince to stop the reaction.

Aluminized Exhuast pipe - buy bends and weld together
pros - avaiable at parts store and I can weld it.
cons - its steel and would rust and potentially get holes inside it. how would I coat the inside?

Black iron pipe - used to gas pipe. Cut and weld 45 degree angles.
pros - can be welded with a mig. its thicker steel than exhuast pipe. Much longer before it rust or leaks
cons - its heavy. will the 45 degree welded angles restrict or slow down the flow of the coolant.


I would much prefer to use copper, but I am worried about the copper joints cracking during normal operating of the truck. The truck will be a daily driver, but will be driven very far from home and do not wish on doing side of the road or a parking lot repair.

Do you guys have any better ideas?

[csuengr]

When I did this for my CJ, I took my radiator to a shop and had them switch the ports. Cost me $75. A proper radiator is the best way. It is doubtful you will be able to use an off the shelf part without doing mods to it.

[jaber]

I too had my stock 4 core changed to fit the Caddy. If you have them clean and check it at the same time, it will be fine for several years. Over time, you can get another to through on the shelf so when you start seeing signs, you can swap them out before a big trip.

[carnuck]

I used aluminized exhaust pipe for mine. Bent it up at Midas and I was good to go! (5 years no leaks till I rolled the truck and punctured the rad with my motor)

[pcoplin]

Cost me $100 to have my radiator tested, cleaned, and outlets moved to the opposite side.

[FSJunkie]

Aluminum and copper within the cooling system together are usually fine if you use GO-5 coolant. Maybe even Dexcool.