An improved modular 
heat exchanger suitable for automotive applications, and particularly radiators for 
heavy duty equipment, and methods for forming the modular 
heat exchanger. The modular 
heat exchanger construction incorporates a brazed core 
assembly composed of flat-type cooling tubes and sinusoidal centers. The ability to use a brazed core 
assembly within a modular heat exchanger construction promotes 
enhanced heat transfer efficiencies associated with the use of flat tubes and sinusoidal centers, as compared to mechanically-joined round tubes and fins. The required positional tolerances of the tubes for 
mating with the remainder of the heat exchanger are maintained within the brazed core 
assembly by eliminating core shrinkage attributable to the use of clad aluminum 
alloy components to construct the core assembly. In two embodiments, core shrinkage is physical suppressed through the use of an expandable 
brazing fixture or the inclusion of sub-headers in the brazed core assembly. In a third embodiment, a clad 
slurry containing a 
braze alloy is deposited prior to 
brazing on a core assembly composed of unclad tubes and centers.