How Worley Make Radiators: A Simple Step-by-Step Guide
How Worley Make Car Radiators: A Simple Step-by-Step Guide
Building a radiator isn't something you can rush. We've refined our process over the years to ensure each radiator delivers reliable performance when your engine needs it most. Let me walk you through exactly how we do it:
1. ✅ Cutting and Bending (Blanking)
Everything starts with premium aluminum sheets. Our cutting machines slice these sheets to precise dimensions (that's what we call blanking in the industry). Then comes the fun part: specialized tools bend these cut pieces into the exact shapes we need. You're looking at future radiator tanks and frames taking shape right before your eyes.
2. ✅ Punching
Here's where our punch machine earns its keep. It creates small, incredibly precise holes in specific components. These aren't random holes; they're carefully positioned for bolts and hoses. Getting this right means your radiator will fit like a glove in different car models.
3. ✅ Installing the Core
The core is where the magic happens for engine cooling. We meticulously assemble these components, ensuring fins and tubes align perfectly. There's no room for error here because even slight misalignment affects cooling efficiency.
4. ✅ Brazing Furnace Operation
Time for some serious heat. The brazing furnace cranks up to extreme temperatures, melting a special alloy that fuses core parts into one solid unit. This step determines whether your radiator will hold up under pressure for years to come.
5. ✅ Core Pressure Testing
Now we put our work to the test. Water fills the core while we apply significant pressure, hunting for any weak spots or leaks. Found a problem? We fix it immediately. Only cores that pass this rigorous test earn the right to continue down our production line.
6. ✅ TIG Welding
Our skilled technicians take over for this critical phase. TIG welding creates incredibly strong joints that won't fail when temperatures soar under your hood. These connections need to stay leak-free through countless heating and cooling cycles.
7. ✅ Assembly Pressure Testing
Think of your car's radiator as the heart of its cooling system. Over time, it can get clogged with dust, leaves, and other debris, which can hinder its performance. Regularly cleaning the radiator's exterior can make a significant difference. The best part? It’s simple and budget-friendly. However, if the inside is blocked, you might need to call in a pro.
8. ✅ Radiator Shaping
Sometimes a radiator needs fine-tuning to achieve that perfect fit. Specialized shaping tools help us make precise adjustments. Your radiator has to slide into your vehicle's engine bay without any wrestling matches.
9. ✅ Polishing and Cleaning
A thorough polish smooths the surface and gives our radiators that professional finish. Then we clean away every speck of dirt and debris. Clean radiators don't just look better; they actually perform better too.
10. ✅ Packaging
The final step requires as much care as everything that came before. Sturdy packaging materials protect your radiator during shipping. When it reaches you, it should look exactly like it did when it left our facility.
We stand behind every single step of this process. Our radiators earn their reputation for dependability through careful craftsmanship at each stage.