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Originally Posted by speedjunkie
That's crazy. How much weight could that possibly save? I know the FD had troubles with the plastic pieces and hot coolant. Did the S5 have this problem too? I have an 87 TII that I haven't built yet. If I'm going to do this I need to start learning. I only know the FD so far.
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Any weight savings are on the order of a few ounces. FWIW, I've got an S5 T2, and the plastic thermostat housing failed. Developed a tiny crack that let coolant out. Rotary13B1.com makes an identical AL replacement of the stock part, that's what I'm using now.
As for the stock S5 radiator, which has plastic end tanks crimped onto an AL core, I never had reliability problems with that. But you'll probably want to replace it anyway with a good AL aftermarket radiator to improve the stocker's marginal cooling, especially if you do a few mods.