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Old 10-18-2012, 10:31 PM   #358
Registered User
Join Date: Oct 2006
Location: Springfield OH
Posts: 740
My Ride: '00 323i + '75 2002
Finished modifying the radiator tonight.

Cut out a plug and welded up the old outlet port:

Then I cut a new hole on the opposite side and welded the new outlet in place:

The last thing to do was to make the internal baffle to make the coolant flow through the plates instead of just down to the outlet. so I cut out a section so I could access the middle of the driver side tank:

Then I made a cardboard template for what I wanted the baffle to look like:

Template turned into aluminum baffle:

Baffle welded in place:

With the baffle welded in place I put the cutout section back in place and welded it as well:

Here's is a pic of it while I was doing the leak test. Luckily for me all my welds held! No leaks. Now that I know my welds functional I just have to work on making them look pretty lol.

And here you can see how the modifications simplified the routing of my coolant hoses. I wish I could do something to move the water pump -> thermostat hose, I may try to fab up a hardline of some kind, but I'm not going to worry about that for now. Also, ignore the wonky bends in the coolant hoses in the pic, I just used some I had laying around. I'm going to try and find some more universal silicone ones that match the needed paths better.

Thanks for looking!
Tinker Engineering - 2014

Mica - 2000 BMW 323i - The one that started it all
Fiona - 1975 BMW 2002 - The Definition of Project Creep
Heidi - 1988 BMW M5 - The piece of BMW history
Silvia - 2013 Subaru WRX - Stock, for now
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