I think this thread is being linked all over the world!
Let's see what could be done to it to make it work, shall we?
#1: use a better pump. This thing is so weak , I'm surprised it move any water at all.
#2: reverse flow direction. Center inlet might improve things a bit, because of the low flow, otherwise, if the flow can get up there, it wouldn't matter.
#3: Increase the rad capacity/performance. There is a provision for a second set of tubes to go through the fins. I think what happened is that the manufacture realized (sometime during production) that the rad was lousy, so he adapted by using a double length copper fin (probably pre-cut parts). Now let him swap the whole thing out with a heatercore-like structure. JessFM could probably hook him up.
#4: use a better fan. I've said it a million times if I've said it once: airflow is critical, especially in this design.
#5: redo the base. It could have a copper cap, with an anodized aluminium body. It'll be more expensive though, but since the manufacture already uses copper, then it won't be too difficult. It'll look prettier too!
#6: the o-ring to the side tanks worry me, a lot. They're not properly used.
#7: the rivet fill point is a no-no.
Optional:
I'd consider ducting this block through a case fan, for much improved airflow, instead of weighing it down further with a massive fan.
I'd consider adding a provision to run an external pump. If it was possible to hook it up to even an Eheim 1046, it would fare so much better.
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