How We Developed Our Renault Clio MK2 Aluminium Header Tank
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How We Developed Our Renault Clio MK2 Aluminium Header Tank
At The Alloy Shed, many of our products start with the same question: how can we replace an ageing plastic component with something stronger, simpler and built to last?
That was the starting point for our Renault Clio MK2 aluminium header tank.
Starting With the Original Clio MK2 Tank
The aim wasn't to produce a generic aluminium tank and call it a Clio part. We wanted something designed specifically around the MK2 engine bay that could serve as a direct replacement for the original coolant expansion tank.
We started by studying the original tank, including its mounting arrangement, hose positions and the space available in the engine bay.
From there, we worked out the dimensions and positioning required for an aluminium version while also looking for opportunities to improve the design.
Developing the Tank Body
Rather than simply copying the shape of the original plastic tank, we developed a cylindrical aluminium design that could be manufactured consistently while fitting within the available space.
The finished tank uses a 130 mm diameter × 150 mm body, giving us a compact but substantial aluminium reservoir suitable for the Clio MK2 installation.
The cylindrical construction also suits the way we manufacture our tanks, allowing us to produce a strong, fully TIG-welded assembly without unnecessary seams or complexity.
Developing the Mounting Bracket
One of the most important parts of developing a vehicle-specific tank is getting the mounting arrangement right.
We developed a dedicated bracket for the Clio MK2 rather than relying on universal mounting straps or requiring the customer to fabricate their own mounting system.
Positioning and clearance all had to be considered so that the finished assembly would sit correctly in the vehicle.
Getting the Connections Right
A replacement coolant tank is only useful if it integrates properly with the existing cooling system.
The Clio MK2 version was therefore developed with the hose connections positioned specifically for the application, including the 16 mm lower connection and 13 mm upper connection.
Each connection is welded directly into the aluminium tank body, creating a simple and robust assembly.
Moving to a Conventional Pressure Cap
Another important part of the design was the filler neck.
Our aluminium tank uses a conventional radiator-style filler neck, allowing the tank to accept readily available replacement pressure caps rather than relying on the original plastic tank arrangement.
We can also supply the tank with a suitable pressure cap if required.
From Prototype to Finished Product
Once the basic design was established, the dimensions, bracket and connection positions were refined into a repeatable design that we could manufacture consistently.
The tank is fabricated from 2 mm aluminium, with the components formed, assembled and TIG welded by hand.
Every tank is produced as a functional component rather than simply a cosmetic cover for the original part.
Why Aluminium?
Plastic expansion tanks are repeatedly exposed to heat, cooling-system pressure and constant temperature cycling. As plastic components age, they can become brittle, discolour and eventually develop leaks or cracks.
A fabricated aluminium replacement removes the ageing plastic reservoir from the equation while also giving the engine bay a much more purposeful appearance.
Made at The Alloy Shed
The Clio MK2 header tank is a good example of how we develop our vehicle-specific products: start with the original installation, understand what the part needs to do, then design an aluminium alternative around the vehicle rather than trying to make a universal product fit.
It's now part of our growing range of hand-fabricated aluminium cooling components at The Alloy Shed.
If there's an application you'd like to see us develop next, get in touch. We're always interested in hearing about vehicles where a properly designed aluminium replacement could solve a problem.