RAD Replacement Suggestions

-have you checked with any other aftermarket suppliers for heavy equipment? near me there's a company ON-TRACK, etc....usually not Cat quality but much more reasonable cost
-what about heavy equipment wreckers? maybe something out a big tractor (or truck)(or big equipment) might be close or be modified to work....

We just had one done for a D5 98J, and had a bit of a wait time (none available) price was about the same as your D6C cost. JM

if you could get a alloy rad about the same size you could mount it inside the old housing so it looked the part. try truck or macinery wreckers they might have something. try aussie dessert coolers or PWR they both do custom stuff for hot rods and other applications

I think I paid over $4000 just for a core for a D7G about 3 years ago, so your prices are not out of line especially with this transient inflation we're all enduring...and I say that tongue in cheek.

Trainzkid88, when you say ALLOY do you mean aluminum rad core? might throw us off course in North America...slightly different meanings..
- my guess/experience.. is aluminum is the way to go, don't know all the options and history of rads... aluminum moves heat as good as anything commonly available..

Normally an alloy would mean a mix of metals so I assume Chris meant Ally which is of course short for aluminum as it is known in North America😊
It is still not as good as copper for transferring heat. There are two main reasons manufacturers went to aluminum and that is cost and weight.
The reason the radiators are smaller probably has more to do with the internal design of the engine.
By the time you get someone to build you an aluminium radiator you probably won't have much change left out of $2500. These radiator's arn't small and you need to do your calculations before diving in and sticking something in there that does not work and you have spend another $2500 on a core anyway.

Normally an alloy would mean a mix of metals so I assume Chris meant Ally which is of course short for aluminum as it is known in North America😊
It is still not as good as copper for transferring heat. There are two main reasons manufacturers went to aluminum and that is cost and weight.
The reason the radiators are smaller probably has more to do with the internal design of the engine.
By the time you get someone to build you an aluminium radiator you probably won't have much change left out of $2500. These radiator's arn't small and you need to do your calculations before diving in and sticking something in there that does not work and you have spend another $2500 on a core anyway.

actually certain aluminium alloys are better than copper and brass for heat dissipation. and yes due to cost, weight, ease of manufacture aluminium has taken over.

a boilermaker i know borrowed a mutual friends stick welder that had aluminium windings, while his was in for repairs gavin wanted to keep it and he explained why as the windings didnt hold heat like a copper based machine of same size. it meant he could work for longer due to the higher duty cycle.

yes niether option will be cheap. where the saving might be is if you can get a off the self unit that is suitable. the [roper replacement core has the advatange you know it will work its guaranteed to fit.

Actually certain aluminum alloys are NOT better than copper for heat dissipation. Even 1050A does not equal coppers thermal conductivity.
https://www.gabrian.com/copper-vs-aluminum-heatsinks/
https://matmatch.com/resources/blog/materials-heat-exchanger/

I think your mate Gavin's borrowed welder was more efficient for a different reason.
You would also need to take electrolysis into consideration with a diesel engine.