Cooling Systems - Did you know if you leave a leakage path, coolant will run out on your parent's driveway?

So, I wrote an earlier post about fixing my radiator and thinking all was well.  As the German's say, don't praise the day before the evening. There is still periodic leakage from the cooling system.  It's the strangest thing I've ever seen in working on cars.  If I drive a short distance, some coolant leaks out.  If I run her hot for a bit, there is no leakage.  Hmm.

Well, I guess it doesn't help that the lower radiator hose is smashed into a bolt.  I don't remember that on assembly and nothing seems to have moved but it is somehow crushed in there.  That hose also seems to be the leak.

I also observed this issue:

That's the heater core return.  It was perfectly routed with no interference as long as the wheels were pointed straight ahead.  If, however, one should turn the wheels, the universal joint on the steering column would come around and scrape the hose.  Between these two issues, I think I came pretty close to puking out all my coolant and calling a tow truck!

Fortunately, I had more heater hose so I was able to replace it and route it a bit farther from the universal joint.  For the radiator hose, I found a stainless steel accordion hose kit.  

I thought that would flex around the bolt and eventually it did but what a job!  There is no room to work under there.  Furthermore, on the jack stands it required staying in a crunch position to reach the clamps.  This I could do for a few minutes at a time until my neck and abs began to quake.  Then I'd rest and go again.  Altogether it took about 4 hours.  I also ended up having to shim up the engine on that side by an 1/8".  It turns out there was another bracket in contact with the frame and that also cleared that interference.  And it looks good.

It might not look like it but there is an 1/8" of clearance above the bolt!  And it doesn't leak so far!

And still doesn't leak after 200 miles and 32 autocross runs!  I'm amazed that it takes several years to shake down an engine swap but it is what it is.  These improvements will allow me to keep having #funwithcars !

I almost pushed the "publish" button on this one.  And then this happened:

I was convinced that I had messed up the cooling hose replacement.  I certainly messed up but not in that respect. It took 3 years for this to happen:

That's the hole that is created over three years of your stainless steel braided oil line rubbing on the radiator housing.  Had I recognized where the leak was coming from, I would have jammed a towel under the hose and things would have been OK.  Unfortunately, I could not figure out the source of the leak.  I thought periodic refilling would suffice.  And it got me to my Mom's house.  

I was then on the hero path.  My brother and I would patch this with supplies from my Dad's workshop, thus closing the circle of car repair and I would listen to high power Fall Out Boy songs as I drove home under the stars!  Almost...

I think our job of patching showed great innovation:

We hammered the steel washer around a 3/8" ratchet extension.  It was a perfect match for the radius of the radiator housing.  It dug right in and wrapped the rubber washer around the corner.  We then refilled the radiator and went and ate dinner.  Because this is a done deal, right?

Wrong.  We attempted an engine start before dessert.  Crank, crank, crank... Sounded close to firing but what's that liquid running out the back of the car?  Ummm, coolant.  It was running out of the exhaust pipe.  There are few ways for coolant to get into the exhaust and all are very expensive and labor intensive to fix.

So, I drove to far after overheat.  Forums have since informed me that you have only a few seconds before the cooling seals melt and the housings warp.  Fuck.  A later check showed that I have 100-110psi compression in both rotors on all sides.  Maybe there is some hope.  

Winter is coming...and I need a workshop project in any case.  One can also enlarge the intake and exhaust ports during a rebuild.  I mean, you can't have too much horsepower, right?

In a similar situation, pull over, call AAA, and keep having #funwithcars !