I leaned on the hose to the expansion tank and snapped off the hose barb. After pricing a new radiator I came up with an easy fix. Here are some notes and pictures of the fix.
I used a very sharp wood chisel to cut away the remaining piece of the hose barb and smooth the area. Using a step drill I drilled out the hole to just under 3/8”.
I removed the top rad hose and ran a thin coat hanger in through the 3/8” hole and out the large hose barb. Don’t let the wire contact the aluminum radiator core
I got a 1 ¼ x 3/8 SS bolt, threaded all the way. Set it up in the lathe to drill a 3/16” hole through the bolt. Next turn down the head to round it off so as to fit through the hole squarely. Remount the bolt with the head in the lathe chuck and a live center at the outer end. Turn off ¾” of thread for the hose to slide on. Place the bolt on the wire and bend over to hold the bolt on. Draw the wire with bolt back through the rad top and out the 3/8” hole. Slide the washer and nut down the wire and fasten. The bolt will make a tight fit in the drilled hole that is just under the bolt size.
Remove the wire out through the top hose barb. Finished

Attached Thumbnails

       

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1984 300SD turbo 126
"My true love"

God made me an atheist and who am I to question His wisdom

Um, can you sell us pre lathed bolts...

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

I am thinking brass bolts would be better

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Great fix
My$.02 Don

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Red Green "This is only temporary,Unless it works!"

97 E300D 157000 miles
87 300TD ?141k? miles

When I leaned on mine and broke the nipple, I tried to do something simlar, but found the plastics in this area way too thin and brittle to be a permanent solution. If it is the original, I would predict all the top plastic to be in a similar state, especially if non MB coolant was used over the life of the radiator.

Watch it last forvever, but don't be suprised if it fails.

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85 300CD Turbo "Das Polluter" 230K sold for $3,000

98 BMW 323is

As a victim of the same snafu (and bought a new radiator) - that's slick! You should make 20-30 of them and sell them.

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~shell
As of 2/2010:
2001 CLK55 0o\=*=/o0
13.6 @ 106mph
10K mi
1984 300SD
260K mi and going and going...
97 S600
46K miles
1991 Sentra SE-R (extremely dorked with)
www.se-r.net

I used quicksteel the first time, but that didn't work out well. Eventually broke it again (performing the same task as last time! When will I learn?) This time I used jb weld and it worked great, no leaks, no problems.

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1985 MB 300D/T

Fell off the WVO bandwagon when people started trying to charge $2.50 a gallon for dirty vegetable oil.

You are all correct. The top plastic is very thin, only 1/16" or less and very brittle.

To build up the area with JB Weld then smooth it out prior to drilling would help. I am suprised that this material will stick to this particular plastic.

Next time I do this job (i hope never) I will file the hole in a down direction to allow more space between the top of the hole and the top inside edge of the shell for bolt head clearance.

I used SS bolt because it won't react with the Aluminum core.

Next time I work on the alternator I will remove the hose from the rad.

If anyone needs one I can make it up and stick it in the mail.

__________________
1984 300SD turbo 126
"My true love"

God made me an atheist and who am I to question His wisdom