Unfortunately there may not be a cost effective option. I would take it to a local radiator shop to have them take a look at it. I had mine done last year and it cost me $800 ('84 Chevy 454) to have it recored (used the original tanks). In my case there were no aftermarket alternatives since the tank is custom with the neck on the front of the top tank rather than the top. It stung a little in the wallet, but it's one of the better investments I made in the thing. It runs nice and cool under all conditions now.
Welllll I just had mine done in my 1975 and after extended discussions it was decided to have mine re-cored. Seems the copper fins cool better than the aluminum ones. That's my two cents. It wasn't all that expensive. I took it out my self and put it in my self.
I R&R'd mine myself, too. Still cost me $800. The guy said the new cores are much more efficient - I don't know the science behind it. Said he only got made in USA stuff, too, which he said is better. The new one is a little thicker which wasn't an issue for me. The guy has been in town for 40 years. Last thing I brought him was the radiator out of my '67 GTO back in the 80s. Thought I'd throw him some more business. So far not disappointed.
I would have to disagree with that TJ. The newer copper cores are coming out of china and are very thin for one thing, my radiator guy actually closed up his business because he refused to use them. Told me they just do not last and anything over a 15lb. cap and there is a real good possibility of it blowing out or ballooning. I put an aluminum one in mine and the difference in cooling was substantial. Much better and my old original was not clogged, it had a couple holes in the bottom from garbage collecting between the AC condenser and the radiator. If you look at an aluminum radiator you will see that there are usually fewer cores but the fins are larger and spaced a little farther apart so they get much more air. They are also nowhere near as fragile as the copper ones. There have been many tests since change comes hard to us old people. I was one of those who believed copper ruled but the tests proved me wrong and my experience also backed it up.
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