SVX Engine cooling "Again & Again"

[icingdeath88]

Originally Posted by Johnybeas

I wanted to see if I could get more info about the crossover pipe, I recall seeing a long ways back in the thread something about the IRIS system not being used on the vehicle this was fitted on so the pipe was able to be straighter. I'm just curious what changes would need to be done to make this same pipe but so it would fit on a vehicle that still has the IRIS and also more specifically what was tapped into (the heads "at the bosses for the front two cylinders on each head and ran hoses to the custom crossover pipes" not sure what Bill meant by this) and how, and what sensors are tapped into the pipe.

The part that's tapped into: On top of the engine block in addition to the two big water outlets, there are also 4 very small water outlets (2 on each side) that water flows through into the stock crossover pipe. Looks like what they did here was weld 2 small tubes on each side of the new y-pipe (gold) and attach hoses to connect them to those small outlets. I think they would have had to tap (like when you add threads to something) the holes in order to attach those fittings to them.

Sensors - basically see svxfiles' post. The two sensors look to me like the stock coolant temp sensors.

[SVXRide]

Originally Posted by Johnybeas

I wanted to see if I could get more info about the crossover pipe, I recall seeing a long ways back in the thread something about the IRIS system not being used on the vehicle this was fitted on so the pipe was able to be straighter. I'm just curious what changes would need to be done to make this same pipe but so it would fit on a vehicle that still has the IRIS and also more specifically what was tapped into (the heads "at the bosses for the front two cylinders on each head and ran hoses to the custom crossover pipes" not sure what Bill meant by this) and how, and what sensors are tapped into the pipe.
Reposting the image to refresh what I'm talking about

FYI -- what you're looking at is the very extensively modified engine that YT built for Dan. This pre-dated Tony's efforts related to modifying the water pump outlet. I don't recall how Dan's engine did when he ran it at Summit Point.

Bill

[bazza]

So we've pretty much sorted what needs to be done to solve this issue with the bigger thermostat cover and proven it's worth on the track. However a minor issue remains and this is the passenger head exits hotter than the driver head (Australian cars). Tony has logged this at being 10'C difference. This really isn't an issue for 99.999999% of people but it can easily be fixed if you're bored and or just want to do a mod. Why not nessecary - recently my ecu read temps never going above 88'C after 65 laps @ a circuit with a turbo EG33 and the ecu reads the hotter head... so I could get away with this forever.

Anyway the temperature difference is due to the pressure of the passenger head having flow restriction due to having to force it's way to the radiator. The driver side has a much easier route.

Also note the EJ2X outlet is far smaller than the EG33 head outlet. The EJ2X outlet on each head is 26 mm, (1062 mm^2 area total) going out a 30mm outlet (707 mm^2 area). The EG33 is 29 mm (1322 mm^2 area total) trying to get out a 30 mm outlet (707 mm^2). So what if we double the outlet and make an easier path for the passenger side head... so today after chatting with Tony I made this up.... yes I know, I spend all my time welding steel and none welding ally so my ally welding sucks giant dogs balls. However this is just a beta version. They will both run into a Y-piece merge that feeds a 46 mm radiator inlet up top, I'll do that with stainless - far easier for me to weld Basically all that it does is give an far easier exit for the passenger head water.

[SVXRide]

Bazza,

Yep, that weld is definitely a case of function over form (giant dog balls indeed!) !

Seriously, it looks like what you've done is a simpler version of what Tom did on Dan's car. Looking forward to seeing how this works out!

Bill

[bazza]

Originally Posted by SVXRide

Bazza,

Yep, that weld is definitely a case of function over form (giant dog balls indeed!) !

Seriously, it looks like what you've done is a simpler version of what Tom did on Dan's car. Looking forward to seeing how this works out!

Bill

Hahaha yeah indeed. I've had a little experience playing with flow rates and radiators... mainly for my heated pool (via a firedrum) so I'm rather confident what I've done will work nicely.


Is that this one? I like the design - if the merge was bigger - 46mm ID or even it would be perfect - although it's hard to tell what size it is, could already be that size?



I think this will be the perfect design, 2" ID even better than 46 mm ID after the merge.


Also for interest sake, going from 38mm pump inlet to 50mm pump inlet increases the cross flow area from 1135mm^2 to 1965mm^2... massive difference. Even 46mm is 1662mm^2.

[TomsSVX]

I almost miss the days of r&d.... almost...

Tom

[torxxx]

We need to find you a new way to mod a SVX Tom?

I got some ideas...

[SVXRide]

Originally Posted by bazza

Hahaha yeah indeed. I've had a little experience playing with flow rates and radiators... mainly for my heated pool (via a fire drum) so I'm rather confident what I've done will work nicely.

Is that this one? I like the design - if the merge was bigger - 46mm ID or even it would be perfect - although it's hard to tell what size it is, could already be that size?



I think this will be the perfect design, 2" ID even better than 46 mm ID after the merge.

Also for interest sake, going from 38mm pump inlet to 50mm pump inlet increases the cross flow area from 1135mm^2 to 1965mm^2... massive difference. Even 46mm is 1662mm^2.

Bazza,

Yep, that is the first step in Tom's (TomsSVX) modification to the coolant system on Dan's engine. If you flips back a few posts (#1292) you'll see the finished product (lines tapped into the main lines). What I don't think you've seen is the inline thermostat housing Tom added in the return line (for that matter, I don't remember seeing pics of it, but then that's probably age on my part ;-) ).

Bill

[Dessertrunner]

Over the last couple of months in between other jobs have been playing with designs for new top pipe which include twin thermostates for cooling. Also a change to the PWR radiator. I was trying to develop the design so it would acheive the following.

- Have a thermostate for each head.
- Two pipes returning to the radiator.
- Use a different type of thermostate, one that when open will close the coolant going to the pump throught the 2 small hoses.
- Thermostates to be located as far back as possiable close to the head outlet.
- In addiation I had been working on a new cross flow radiator design that could be built by PWR (then you guys in the USA could get it) but have since found a way to acheive the same thing with a top and bottom tank design still made by PWR.
- Review pressure loss in the sytem and attemp to reduce that loss so the system can cope with the higher flow of the pump running at 10k. Current engine means that 1/2 of the pressure loss in the system is from the back top of the block were the coolant comes out of the heads.

When I get it onto this issue I will post updates.

Tony

[shark_22]

I'M planning to built my own thermostat cover but just to be sure It's 45mm ID? and your OD is 50mm?

thanks

[bazza]

Originally Posted by shark_22

I'M planning to built my own thermostat cover but just to be sure It's 45mm ID? and your OD is 50mm?

thanks

My cover is 2" (~50 mm) OD. However the radiator outlet is 46mm OD so I step down slightly.

[shark_22]

^^
ok, and somebody know if the oem housing( not the plastic one) of the wrx, sti ,ez30 are bigger than the eg33?

[SVXRide]

Originally Posted by TomsSVX

I almost miss the days of r&d.... almost...

Tom

Tom!

Can you post a pic of the inline thermostat housing - and specs for it - that you used on Dan's car?

Thanks.

Bill

[Dessertrunner]

Guys just about finished a thermostate housing that welds to the end of the top pipe along side the power steering pump. Have been stuffing around with the GCode on the CNC lathe so I can run up a number of these units at once as I will fit them to all my cars.
See if we can get photos up today.
Tony

[Dessertrunner]

Here is photos of the top aluminium thermostate holder.
As you can see it has the following advantages:-
Its welded to the top pipe,
Its tucked away from the power steering pump etc,
The thermostate is easly accessiable.
Doesn't effect the rest of the engine plumbing.
And you can chose your top pipe size by changing the out let cover.
Its a really neat and tidy soluation for engine reving up to 8K.

Happy to answer any question, I will need to discuss this with Bazza but we maybe prepared to sell units to others. If you are interested let Bazza know and depending on demand we will consider selling them to others. Haven't sorted a price yet but we don't aim to get rich.
Tony


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