Repairing Aluminium Radiators...
Discussion
For a Cu/brass rad you'd normally repair by soldering. Obviously not possible with Al, so you'd have to braze, but only likely to be feasible in a few cases. For a DIY you might try epoxy but I think the chances of getting it to seal are small. Al radiators are usually pretty tough (I've seen them literally folded double round a tree stump and still holding pressure), but cross flow designs are sometimes susceptable to fatigue due to differential thermal strains. If so, a new one would be your most realistic option.
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