My radiator appears to have served out its useful life. Pinhole perforations in the upper flange leaks under pressure. Could be repaired but who knows where the next holes are ready to appear. Anyone had any good/bad experiences with reasonably priced replacement alloy radiators? If so, where did you source the radiator approximate cost?

Im changing out my radiator as we speak due to a blow out of a cheap radiator. It lasted 10 months before it began leaking coolant from either side of the core. This radiator was $150 from Autocool Warehouse, which is a company down in Victoria who manufactures their radiators in China...I figured being an Australian company they would have some quality control. Any whom I have now gone with a radiator from PWR as I figured its not worth a blown motor over going cheap again. 

I personally wouldnt bother with the cheap ones and the risk that inherently comes with it.  

I think most builds use the genuine toyota one, pretty sure 2quik uses one and reckons that the factory one is more than enough. But I could be wrong.

I've seen the result of "saving" money and using a "more economical" eBay radiator. Bite the bullet and either find a good genuine 2nd hand ( and get it thoroughly tested ) or talk to PWR.

Radiator delivered from PWR  today for my SW20. about 95mm too wide and the cooling fan shouds dont line up. Mine is about 675 wide and supplied radiator is approx 760mm, my fan shouds are 200mm centres with 95 mm between the two centre mounts. Anyone know if 1991 radiators were smaller. PWR  have 685 listed as Aw10, 760 listed as SW20. Anyone hae an old radiator asround they can run a tape over please

PWR rad in my 91 GT no issues.  I'm not sure where my spare stocky has got too atm (moved not long ago and Grace packed it) or I'd measure it for you.  That said all the rad hoses lined up so I know the inlet/outlet positions were pretty much bang on in mine.  What PWR part number have you got?
 

I know there is 2 different sizes for the sw20. Not sure what measurements are or which cars had the smaller one

The one in mine (96 turbo) is 760mm wide
 
I think it might have been dauris that has posted up about this before
 

Factory one is fine but getting old of course. SW20 rads are quality, not blingy. Personally, I wouldn't object to a pwr rad although I have heard of one or two issues with them. If only Koyo made SW20 aluminum rads.

In your case, go pwr or a good 2nd hand unit. Wouldn't bother with anything else unless it's some rare quality Jap aftermarket SW20 rad.

Highlander, was your car originally an N/A? If so I believe the n/a cars had smaller radiators and fans.
Last pwr rad I bought fitted my 1990 turbo import perfectly. Awesome quality part aswell!