It's nice that you guys come out here on the forums and talk openly about this stuff, kudos for that
Some notes:
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Originally Posted by CSF Inc.
We've sold over 250 of these units since they came out, and I would say 75% of them have had zero fitment issues.
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Keep in mind a lot of people probably never report the fitment issues. I bought mine through Z1 Motorsports, had to dremel the hell out of the rad core support to fit it, but figured it was normal based on the forums. I suspect the rate of fitment issues is a lot higher than 25%, given how much dremel cutting and grinding I had to do.
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As far as the drain plug goes, we're using a harder type of aluminum alloy as well as upgraded washers. I know this was a problem in the past.
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I haven't had any issues with my drain or airbleed plugs. The washers appear to just be fat black rubber ones (I guess this is the older washer?) which squish out when you tighten them down, but the threads on the aluminum plugs seem to seal well enough to make it a non-issue (and/or the rubber Just Works for now).
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Honestly, the warranty rate on this product is higher than any of our other models, and I'm a little puzzled why? They are all made to the same standards, same inspection and testing, at our same factory by the same people. Normal warranty rate is >2%, but this unit is about 3.5-4%
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If I had to guess, I'd say the fitment and warranty-rate issues go hand in hand. When you have a sizable chunk of the users cutting on the rad core support for fitment, that creates two warranty-inducing issues: (1) They have to take the rad in and out of the car 10 or more times during one installation for test fitment trying to get the posts to line up and doing more filing and cutting, etc. This probably increases stress and damage potential right off the bat during install. (2) Even when they're done, the fitment probably isn't perfect, it's just as close as they could get it when the posts + mounting bits finally barely fit together. Basically part of your design is now coming from random customer fitment work, so that's a huge source of randomness there.