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And may this find you well too, Jay.
Funny coincidence, I've worked with labs and just happen to have acquired a collection of said rubber stoppers. Of course I originally thought of just stuffing one of those stoppers in by itself, but naturally it could just end up blowing out at some point. Even though I thought about expansion plugs, I simply didn't put those two thoughts together as you did. Your detailed solution is, as always, an ingenious one. Thanks.
In the meantime, it looks like I've been able to source a plug for the job from an auto supplier. The required size is 2 cm (just over 3/4"). These expansion plugs are barrel shaped (as needed) rather than tapered (as a stopper would be). The price is also right at just a few dollars and I certainly don't mind waiting a day for one to be ordered in. For future reference to those reading this thread, it's a Papco 3/4" expansion plug p/n 263548.
As a note to Carlos. I went to a yard today to see about using on old one. Unfortunately there are no pick-n-pulls around so I'd have to pay the going rate for a used sensor (like $35) plus I'd need a new rubber bushing (close to $10 from Volvo) as an old used one shouldn't be trusted and they're difficult to remove without damaging them. The only other thought I had at that stage was using a new rubber bushing and stuffing an old spark plug in it to expand it. That ought to send the next owner's mechanic into a quandry, especially if I run an ignition wire from it to some invisible location, but I digress.
If anyone connected with Nissens ever reads this, why the devil don't you just include a new rubber bushing (almost always needed) and a plug (needed for all 940's with Bosch FI) as standard items with all these rads, rather than separately orderable items? Shouldn't cost more than a whole $3 to do that in quantity and it would certainly simplify all the catalogues out there that lump all 1992-1995 940 non-turbo Nissen rads together without properly listing and clarifying the need for these bushings and plugs. It's bad enough many of them still describe a heavy duty all-metal rad when in fact those are no longer available and only come with plastic side tanks. Whether the plastic sided Nissens are significantly better or worse than the original Volvo plastic sided tanks seems open to debate -search for previous comments here on this topic.
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Dave -940's, prev 740/240/140/120 You'd think I'd have learned by now
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