Thanks for all your suggestions and expressions of empathy. I'm going to keep the broken radiator -- who knows: someone somewhere may someday have need for the upper tank or the core and I may be able to help him out.
I've thought about using JB Weld to repair it, but honestly, i'm not sure it'd withstand the forces associated with installing and removing the hose, let alone the pressure on such a large area as the gash in the radiator now.
Firemanpat, I'm intrigued by your repair -- well done for avoiding the cost of a new radiator!
TheKid said:I don't know if it will work but Rapid-Fix looks promising. In their video they repair a cracked plastic radiator. You could always E-mail them a picture of the broken area and ask if they think it would work. For $30 it might be worth a shot.
If it's feasible, I'd embed some aluminum flashing/ flexible plastic to span the seam. I'll bet it'll be stronger than OEM.Alrighty then. I just reattached the hose port to the radiator with JB Weld. The fit wasn't as clean as I'd hoped -- the plastic on the port was somewhat deformed from being torn away -- but hopefully it'll be good enough.
I'll add a second coat around the seam tomorrow and reinstall the radiator Friday or Saturday.
We'll see...
I always try to remind folks that JB weld is a good insulator...for those times when a wire has to go through a case like on old generators, etc.