Thread: Urgent - Corrosion + radiator hose = no seal... how to fix?

My brothers car had a similar issue. Once cleaned it had masive holes in it. Being an old fiat the mechanic couldn't get a replacement so molded it with the liquid steel. Once finished it looked like new.
The trick is to build it up with a few layers and sand it back so it keeps it's shape.

Yep, use liquid metal. I use stuff called Devcon.

In extreme cases, where the tube casting is almost all gone, cut it back to a flat surface, even it out with a file and then drill and tap to fit a two bolt flanged thermostat housing off whatever car will suit. Gasket, silicone, 12 hours to dry and Bob's your uncle. This doesn't work on every car, as often there's not enough room, but doesn't sound like your is that stuffed.

But if it's that bad you're likely to have even more problems.......

My dad and I have always used Permatex No 3 for sealing hoses to alloy. It creates a seal and stops the corrosion.

Thomas