The paper presents the design, development and unique packaging of vacuum brazed aluminum radiators (VBAR) for Ford's Ranger, F-Series and Aero-star light trucks. VBARs represent 75% of total light truck radiator volume. The VBAR provides significant improvements in performance, weight, cost, durability and reliability when compared to a copper/brass radiator. In addition, the paper addresses core matrix optimization, radiator sizing computer program and product design verification methods which include various corrosion test criteria. Benefits of finite element analysis on plastic tanks at an early design state are also discussed.