Re: Enlarged end tank = combined rad+res?
Unless your fill port is also the highest point in the loop I'm not sure what you gain by this.
I think GlassMan had it right...simply adding a stoppered bung to the lower plenum would be a lot easier than replacing the whole plenum, but even that seems like a lot of work just to replace a simple t-line fitting.
Your design doesn't really qualify as a reservoir anyway as it doesn't really affect the volume of bubblefree water at the pump inlet.
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