From: Greg Stevens [email protected]
Date: 18 Feb 2002
Time: 19:40:06
Remote Name: 203.1.72.96
Ok, we ARE on the same planet. The standard procedure is as you described. The "neck" generally has no reduction or flange on it, but the hole is cut smaller, then flanged out to the correct size. For an 1 1/4 filler neck I would use a 1 inch hole saw then a drift to open the hole out turning a 1/8 flange down inside the tank. This doubles the solder bond area, this is always the part that leaks as it is continually stressed when removing and refitting the radiator cap.
I hope I don't create a world of Austin 7 radiator experts here, don't need the competition! The filler is generally straight sided so it can be raised and lowered to set the cap at the right level to the surround.
Greg.