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Keeping It Cool! Flex-A-Lite Aluminum Radiator - 4-Wheel & Off-Road Magazine

Kevin McNulty Former Editor, Mud Life

It might be cool to run an old, rusty, leaking radiator while plugging its leaks with snake oils and Stop Leak, but there's nothing more frustrating and disconcerting than hitting the trails and highways for an adventure with a vehicle that's overheating. Especially when a breakdown might leave you stranded in a remote or dangerous situation! Your overheating rig is a major pain for everyone you're traveling with. Continually having to stop and wait for the engine to cool before you can hit the road again is not only an inconvenience, but prolonged overheating will damage an engine and shorten its life.

131 1101 Keeping It Cool jeep Cj 8 And Flex A Lite Radiator Photo 35045457 Flex-a-lite manufactures a high-quality aluminum radiator that will provide years of dependable service. The radiators are available for all types of engines and use the company's cross-flow design, which absorb heat and then radiates it through the tank's external fins.

Flex-a-lite manufactures an extensive line of aluminum radiators for just about every type of vehicle, including custom applications. We've had a lot of experience with the company's radiators over the years and have found them to be reliable and easy to install. Flex-a-lite also produces a trick line of electric fans and external coolers that help keep an engine and transmission running cool and reliably. The company offers a one-stop shop and can provide everything needed to help keep a rig's cooling system run at optimal temperatures. Flex-a-lite's radiators are available to fit trucks, Jeeps, and SUVs.

Finishing up the cooling system on our Scratch-Built Scrambler project, we ordered a larger-than-factory radiator that will fit in a Jeep CJ grille and help keep the 5.9L Dodge Magnum engine running cool. The Magnum series of engines has a tendency to run hotter than others, and a spike in temperature could quickly push the powerplant into the danger zone. We've always felt comfortable using Flex-a-lite radiators on our projects and V-8 conversions.

We recruited the guys at Overkill Engineering to help install the cooling system since they have many years of experience in custom engine swaps and builds. With the aluminum radiator bolted in the front of the Scrambler we're sure we won't have any overheating issues, especially while blazing across a hot, dry, remote desert on an adventure.

PhotosView Slideshow The radiators use a two-row core design and come in three core sizes with inlets on either the left or right side of the tank. Custom inlet and outlet locations can also be ordered. The radiators make it easy to swap a worn-out old tank and are also available in kit form with an electric fan. Higher-than-factory CFM beltdriven fans are also available.
Flex-a-lite also offers a trick variable-speed controller for the electric fans. The control unit senses coolant temperature and can sets the fan speed from 60 to 100 percent, depending on a built-in fan thermostat setting. The thermostat range can be set from 155 to 220 degrees F, which allows greater control over engine temperatures. Radiator and fan mounting brackets come with the kits or can be ordered separately. The brackets make it easier to mount both the radiator and the fan and save time because you don't have to fabricate custom mounting brackets.
The external fins designed into the side tanks of the radiator are actually T-channels, which make the tank's perfect attachment points. The T-channels use flat-head bolts that slide up or down, making them fully adjustable and easier to mount to core supports. This mounting system also makes it easier to install overflow tanks, fans, and other coolers.
Many different electric fans are available, including dual-fan systems. The single-fan setup for our Scrambler's cooling system came as a kit and was simple to hook up due to the color-coded wiring. Electric fans may save some horsepower and give the engine a little better fuel economy. If a rig will be used in deep-water crossings, the fans are easy to shut off so they won't be damaged when submerged.
We mounted the variable-speed control box on the side of the radiator core support, which kept the wiring between the fan and the control unit to a minimum. We recommend using high-quality heat-shrink type connectors since they make the connection point between the two joined wires stronger and will protect them from corrosion better.
We have always found these inline temperature sensor couplings easy and cool to install. They make adding a temperature sensor safer than jamming a probe through the radiator's core, which would risk damage.