In the words of my daughter: Eww... Icky.

OK, now it was getting interesting. How did this kind of goo get in the coolant system and why did it end up here? The stuff scraped away like it was a medium density plastic and it was sorta green under the rust colored surface. I figured it must be deposits from the antifreeze. This must be leftovers from a corrosion type reaction between the hose and the fitting or antifreeze. Showing these pictures to a friend at work who sees aluminum corrosion on 40+ year old aircraft all the time confirmed this. It really floored me though, I've been working on cars for most of my life and I've never run across something like this before.

The gunk cleaned off easily enough with some scraping and wire brushing. The aluminum was badly pitted at the surface. I tried filing it down to smooth it out but the pitting was so deep I ended up digging in more than I intended.

No problem though, I've been in this sort of fix before. JB Weld to the rescue! Many years ago I "temporarily" fixed a hole in a radiator end-cap with JB Weld. I always meant to go and solder a proper patch there, but two years later it never leaked. The car was a beater anyway so I just left it.

Also, it was a good thing I decided to fix it. Looking at the hose I don't think it would have lasted much longer. There was a nice split right where the bump was before.

So with a new bypass hose and a reconditioned housing, I can finally sleep better at night.

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