Talk Morgan Forums Morgan Sports Cars Morgan Plus Four, Supersport & Plus Six (CX & CXV Generation Vehicles) Morgan Radiator issues — Again!!!!!!!!!!

MMC picked up the rad tab otherwise it would have been £1200+ extra.

Good luck with the fix.....

The best systems in world can either be brilliant or goats depending on the actual execution of the design and the inherent nature of the components
used. It will all LOOK the same but the difference can only be determined with usage. In other words two seemingly identical systems, made by different
companies, can produce wildly different results. Is it known where the systems usually leak from?

gmg

Here
https://tm-img.com/image/zgSKN

Or here

That's an interesting design. Offset pipe looks odd. If the hose connection is central then why the added welded extension to the end of the tank? I've not seen that on the rads we made in the factory. The inlet/ outlet pipes were high temp hard soldered to the rank with a spot weld for added strength. Rubber hoses provided flex capability in the vehicles. It looks a very solid structure but how does it cope with vibration? I haven't had a close look at my Plus Four rad ( no leaks after 10k miles) yet but what flexibility is there to prevent stress/fatigue cracking ? If a solid coupling then perhaps a hose to give flexibility would help. The core block looks a standard tube/ gill structure with tube plates. Are the tanks soldered/ welded to them or clamped with seals?

Another view

Interesting. The white mess along the tank to core tube plate joint suggests that seal is failed. Also in the first photo a possible leak from the pipe/tank joint. So, either poor design, assembly, fitting, stress vibration or a combo of these.
We made rads for Triumph Acclaim cars ( early 1980's) and these had plastic tanks clamped to the core tube plates with a silocone bead as sealant. The core tubes were expanded into the tube plates to give a tight seal. Two rad sizes for 1.3 and 1.5 engines.All our other rads were brass tanks soldered to the tube plates with the inlet/outlet pipes spot welded in before high temp soldering to seal.Every rad was pressure tested in a water bath and simple repairs could be done, then spray painted. Large scale production of Rover, Land Rover, BL, JCB, Caterham, London Taxis plus rads for repair trade for Ford, Vauxhall etc. Buses, lorries, "specials ( inc military and free standing units. We even refurbed a Spitfire core for the BoB Flight once. Heater cores/ units, expansion tanks also made. Factory is still going.
Back then I remember 2000 Landrover rads a month, 2800 mini rads ( original mini) Marstro, Metro etc. occasional small volume builds of older dars like Maxi, Princess, Morris Minor. Orders for after markets Marston, Halfords etc. Interesting scheduling for JIT to say the least!

The color of the cooling fluid is more green but it was a picture with my smartphone. And if i remember on the second picture the top is below and the the fluid running down

Morgans are "hand built" so scope for variations during assembly. My 2002 Plus8 needed a bit of adjusting to the rad mounting as there was some mis-alignment in mount points resulting in stress on the top fixing bracket and the weld failed ( aluminium) so it was peeling off the top tank. No leaks. Rather than fiddle with the top wing brace I made my own top bracket to fit over the top with padding, rather than adjust the top wing brace It worked well so left as it was. The rubber bobbins at mount points were ok so not replaced. Plus 8's had a reputation for overheating. Mine only did when the fan failed but I did small jobs to improve airflow to reduce the frequency of the fan kicking in. In my view the rad ( Morgan aluminium) was on it's limits for cooling capacity so the fan came on in slow traffic too often. No overheating but a noisey pia!