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Old 27th November 2008, 17:47   #1
kaiser
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Default Metal thermostat housing V6

Fed up with the plastic, I did this. All metal. So what can we say?

YES WE CAN!therm1.jpg

therm2.jpg

therm3.jpg

therm4.jpg

therm6.jpg
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Old 27th November 2008, 18:43   #2
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Kaiser, you do realise we all want one now:lol:
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Old 27th November 2008, 19:06   #3
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Looks to be a very well made component. when are they going on sale !

I presume steel is the material used, with quite a lot of welding needed as the thing has to be made out of commonly available "jobbing workshop" material.
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Old 27th November 2008, 19:22   #4
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Are you ready with your order book for a "group buy" yet?
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Old 27th November 2008, 19:40   #5
kaiser
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Yes, the material used is mild steel, mostly in thick walled tube. The interconnecting straight piece is made from a piece of round bar.
I have used a lathe, hacksaw, welder, paint, normal tools, swearing, band aid and half a case of beer. It has taken me the best part of a week!
The thermostat itself is a 82 degree from a BMW.
It is not too difficult to make. All the sealing areas need to be machined to ID 37.4 and the part fitting in about 37mm. Then you need an O-ring to seal it, seated in a 3x3mm groove. The seal works amazingly well.
The hardest part was getting the fit right, and getting the big holes drilled in the pipe. Welding the darn thing was easy. Making it leak proof was not! (My welding is maybe not as hot as I thought!)

I am still thinking of making a cast brass or aluminium unit, but my set up cost makes it necessary to get about 20 units ordered minimum.
The cost of the units would then be in the region of 150 Pounds. With volume, we could get it down.
The advantages are.
1. You can select any thermostat temperature.
2. The unit will not crack or leak with age. All plastic is verboten!
3. I have mounted a temperature sender right in the centre. Can be used for add on gauge.
4. You can replace the thermostat only, keep the housing.
5. I have modified the bypass valve, so that it blocks return into the engine at 70% of max opening, as opposed to 100% standard, I hope it provides a wider margin of safety.
6. I have allowed a little by pass by the thermostat, even fully closed. That should lessen vapour lock, and give a little bit of protection if thermostat gets stuck, and lessen any shocks, thermal and temperature. A bit longer warm up might be the result.

I can't tell you how it works yet, because I have not yet put the engine back together. But I will keep you all posted. I'll jump out of the window if it doesn't!!!!!

If there are enough people intersted, I will get some units cast. Let me know, but budget at around 150 for housing, pipe and bend. The final cost can be determined if and when orders are placed.

But let us first see how it works. By the end of next week I would imagine I should know!

Oh, and yes. I am busy with a level sensor, which you can build from funny things most people have lying around! More of that later.

Last edited by kaiser; 27th November 2008 at 19:48..
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Old 27th November 2008, 21:51   #6
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Excellent Job.

Next, manifold and VIS valves...
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Old 27th November 2008, 23:04   #7
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looks a nice bit of kit, well done!
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Old 27th November 2008, 23:17   #8
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fantastic,you can put me down for one,and sure more will follow.job well done!
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Old 28th November 2008, 00:15   #9
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Default thermostat weak joint

http://forums.mg-rover.org/showthread.php?t=272757
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Old 28th November 2008, 00:33   #10
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Quote:
Originally Posted by workaholic_ro View Post
This being a method to seal a new or 'good' OEM thermostat. Impressive effort nevertheless and I hope it works well. Kaiser's effort above is to manufacture an entirely new 'stat using better materials. Good luck to both of you in your efforts.
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