Hello,

My mk.3 orion has a black-top ZVH (therefore a CVH water pump) and the larger zetec radiator (that extends further down meaning that the bottom radiator hose connection is further away. I am using this radiator as I have upgraded to an alloy radiator), therefore as I could buy no hose off the shelf, I have resorted to using a hose joiner to extend the hose.

I have tried lipped 32mm hose joiners, and unfortunately if I run the car until the engine fan kicks in, the hose will start leaking (rather dramatically) at the join.

The current hose is made up of (all silicone hoses) a mk.3 escort hose, then a t-piece (from a mk.4 CVH hose, for the thermostat bleed (I have no heater matrix)), then a straight section so that it can go over the alternator.

I am going to try barred hose joiners and Blue RTV high temp sealant next. I am using very good quality Mikalor hose clamps and they are very tight.

I have ordered a zetec engine bottom hose to see if that would be longer and better.

The standard CVH hose is too short with the zetec radiator, and even before I fitted the new radiator would pass too close to the alternator.

Does anybody have any other ideas of how I could prevent this leaking, or any other experience in re this?

It is rather strange that one of the joiners is leaking and the other is not, I have tried changing to different hoses, positions and clamps, and the only constant is the joiner itself. What would be the best type of joiner to use in the situation lipped or barred?

I need a quick dirty solution for next week, and a permanent solution later on (such as a bespoke hose).

Any input is welcomed.