DIY How to fix a crack in a radiator easily. Let the engine cool and remove the coolant filler cap to release any pressure. Clean the area thoroughly around the crack and sand with 100 grit sandpaper about an inch bigger than the crack on all sides. Sand down to the metal, when done sanding clean sanded area and crack with rubbing alcohol. Apply a liberal coat of metal epoxy (J.B. Weld) over the damaged area. Cover a much larger area than where the crack is with the epoxy but stay only on the areas you have sanded and cleaned. I did this repair on my friends truck, took about 5 min. He had to wait 30 minutes to start his truck so the epoxy could cure. The repair worked great and saved him the cost of having to buy a new radiator.

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