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Old 09-03-2012, 06:47 AM
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Can I fix this?

So, Saturday morning I am underneath the hood of my truck tightening the downpipe clamp from my turbo, finishing up my dual exhaust install when I lost my balance and slipped into the engine bay where my hand went between my radiator and air box. I got a few small dings and scrapes, no worries. Then I notice the small nipple fitting on the overflow from the radiator return to the coolant bottle is snapped off. In the meantime I placed a small screw in the hole and and sealed off the hose with a bolt and hose clamp. I have had no leaks but I have not used the truck really either. My question is, does anybody feel that it is possible to drill and tap the fitting and insert a brass fitting wrapped with teflon tape and then re-attach the hose to the brass fitting? All help and input is appreciated.
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Old 09-03-2012, 07:03 AM
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Yes you can. I just had to do this my self. I broke off that stupid plastic nipple when I put my coolant filter on. Get your self a "Q" (.330 drill) and a 1/8-27 NPT tap. Also get a brass fitting with 1/8-27 NPT threads. I found a really nice one at lowes in the plumbing section. Its about 2" long as is the same OD size as the plastic nipple. Drill and tap a new hole. Be carefull the radiator is only about 3/16 thick and its all plastic there. I coated the drill bit and tap in grease to prevent any shavings from going into the radiator. MAKE SURE WHEN YOU TAP THE HOLE YOU CHECK THE TREADS SEVERAL TIMES. Pipe threads are tapered, you don't want to go too far. After tapping the hole, put some teflon tape on the new brass fitting and screw it in. I have put several hundred miles on my fix and havn't had any issues.
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Old 09-03-2012, 07:05 AM
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Yes. Something similar happen to me (minus the fall). I tapped it, installed a brass fitting, and used JB weld instead Teflon tape. Its been two years and no issues.


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Old 09-03-2012, 03:58 PM
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I broke that nipple also. I drilled and tapped it and installed a nipple w teflon tape and hose clamp. Been working just fine. Take your time and go slow with the tap.
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Old 09-03-2012, 04:35 PM
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Old 09-04-2012, 03:24 PM
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Awesome guys. Thanks for the response. I am just glad that we were all really in the same ball park as far as a fix was concerned. I work for a company that has a lot of machinists on hand and I have quite a bit of experience as well, but even better is that the foreman happens to be my cousin (a tool and die maker) and he happened to be available. He too used a grease as well as beeswax for lubrication and to hold the shavings in place. A small vacuum, some teflon tape and some other adhesive(not JB Weld and not that there is a thing in the world wrong with JB Weld), and a brass barbed fitting. I took careful note of his care and I am confident that it was a simple a fix as I thought it was, it was just nice to have someone who earns a living fixing screw ups, major and minor, for a living. Thanks again guys.
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