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Does anyone know whether Rotax welds their cores to the header tanks or uses epoxy?

I have a 2016 Pipistrel which has lost coolant from the get go.  As the loss slowly became worse I eventually was able to identify the source as a porous weld between the top hose stub and tank.  The aircraft of course was out of warranty by the time I identified the source of the leak, and Pipistrel's solution is to offer to sell me a new radiator for $1,000+.  (It is basically a stock Rotax radiator with the stock outlet blocked off and a new outlet stub welded onto the lower corner of the outlet side tank).

It should be easy to reweld the inlet stub except that the heat would destroy an epoxy core-to-tank seal if that is how the tanks are assembled.

Does anyone have experience with the made in China, all welded aluminum knock-off Rotax radiators available on EBay for $185?

  • Re: Rotax radiator leak

    by » 6 weeks ago


    When my Rotax coolant radiator started to leak I took it to a local automotive radiator specialist who fixed it for me and it has been fine ever since. I think that they welded it.


  • Re: Rotax radiator leak

    by » 6 weeks ago


    I don't think Rotax makes radiators. They are aftermarket.


  • Re: Rotax radiator leak

    by » 6 weeks ago


    Where exactly was it leaking?


  • Re: Rotax radiator leak

    by » 6 weeks ago


    Sam, it is often quicker to use incorrect speech shorthand such as "Rotax radiator" than the correct "The unknown Rotax subcontractor who manufactures radiators for Rotax to Rotax' own specifications."

    I'm simply trying to ascertain (1) whether the cores on the radiators supplied as "Rotax" are epoxied to the tanks or welded, and (2) whether anyone has experience with the EBay knock-offs advertised as "fully welded."


  • Re: Rotax radiator leak

    by » 6 weeks ago


    Richard the guy I share my hangar with got an ebay unit and before he fitted it (and modified the mountings) he pressure tested it to find it had a pinprick hole in one of the welds.

    My experience with chinese  inverters, generators and some electronics is you buy 3 of theirs in the same time you would if you bought one from a reputeable supplier so its a false economy.

    My mate then went to a local radiator manufacturer with his original faulty radiator and asked them to manufacture a replacement. He told them it was for his car heater system.

    While you are there just check the milivolt  readings between say your radiator and the crankcase, your radiator cap and the crankcase. These results may cause you to earth them back to the crankcase if there are voltages which will be causing electrolysis and corrosion.

     

    Regards.......Chook.


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