davidn,
WOW! I guess I'm the naive consumer...I wouldn't expect them to make things that the end user had to modify to work right. I would consider this a manufacturing flaw and to heck with the warranty.
If an aluminum casting is porous enough to leak coolant, it isn't a good casting. I would call again and try to get some satisfaction. This forum could be a pretty good sounding board for bad press regarding Clifford products, you might mention that to them.
Stuart
