Well, I took her out for a few days, but hours of

this - Youtube

and this - Youtube

broke open the large crack on the return pipe again.



The smaller soldering held well.



I ended up getting a new radiator locally. It was a little larger than the original one, and had extra fittings, but fitted right into the space and only needed some new mounting holes drilling. I lifted it 1cm to get clearance over the chassis rail, and all but one section (yet to be padded) of the steering pipework is well cleared - no modification needed. This rad has exactly 1 liter higher capacity than the old one - so I'm hoping it'll do the job ok. I split the shroud and mount it in 2 pieces, but again - no further mods needed. It went on very easily and clears the fan all round, but is a little smaller than the surface of the new radiator.

New rad on the right


extra fittings


new holes


clearances






I have no idea what this radiator came from other than it's out of a Mitsubishi, don't know which model, but the temp guage now barely moves from rest, even sitting in traffic in 40' shade temperatures.

Sorted.