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Ques. about single pass

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im guessing the barbs are on the bottom? there shouldnt be, as long as they are connected in a little resevoar type thing like found on the ends of a heater core and similar. maybe a pic would be better, or a model # if you have one.

but it shouldnt be a problem gettin them turned. might hirt flowrate a little tho.
 
This is about what it looks like, id put the barbs in where they are "drawn" in
 

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JBWeld works awesome for cold repairs, just rough up and clean the surface well with some coarse sandpaper first.

For the existing holes, you can hacksaw off the tubes flush and JBWeld a penny over the hole (for 5/8" holes).

Do your drilling of the new holes and removal of the old tubes first, so you can wash out any bits of metal from drilling.

The rad shop is a great plan too, but for me it's a 40 minute drive either north or south :(
 
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