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Have you talked to IPD about taking the radiator back? For what (I can only imagine) they charged you for it, the build quality should be a bit better.
I know what you mean by the lower hose neck - Even on a correct radiator, the lower hose sits very close to the frame rail, making it a bit difficult to fit the clamp.
But what I find odd is the screw-in temp sensor. I have a 90 740 and it's a push-in type of sensor with a new rubber grommet generally supplies with the new radiator.
Stuffing a cloth in the T-stadt hole should be OK, but a tiny bit of PB Blaster inside the water jacket should really hurt either.
Yes, there should be a gasket on the T-stadt housing.
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