TheSamba.com :: View topic - Alternative (DIY) Aluminum coolant Expansion tank

Sat Feb 27, 2021 2:53 pm

Well, after literally months of waiting for the 1/4 NPT aluminum bung to arrive from Canada........ (Lost in the Christmas Mail somewhere)

IT’S IN !!!!!

I installed it myself. I was searching on welding Aluminum and I don't have the welder nor am I going to buy one at this late stage in my life!

I stumbled upon reviews on and "how to's" on using Bernz-O-Matic aluminum welding rods.
This is a low heat process using only a propane torch. Other torches apparently produce way to much heat unless you are doing it on a major heat sink.

Anyway, it is less like welding and more like soldering Copper Pipe only there is no, none, zero flux.
It is imperative that the aluminum be clean Clean CLEAN!
I used a small stainless steel brush and once finished cleaning them I treated the parts like a halogen headlight bulb, don't touch it with your fingers!

You don't weld it in the heat of the flame but there is a perfect temperature window, you heat up the metal and once the rod starts to run remove the flame and work with the residual heat, reheating as it cools.

It was quick and easy. It will easily hold the 15 lbs of pressure that will be required of it.

All finished, the low level probe extends about an inch into the tank.
I placed the bung where I did because if mounted on the other side of the vent nipple, your fingers would hit the sender when removing or installing the radiator cap.

It is about 1/2 the volume of the plastic one.

It will mount in the same location using a length of angle to support it.

Dave

Sat Feb 27, 2021 5:56 pm

wow! that solder/weld looks great!! it'll be just fine and is encouraging to see it so nicely flowed.

i've tried that stuff on an AC condenser and the solder just rolled around without sticking. i think it was AC oil contamination that kept oozing out confounding the process.

Sun Feb 28, 2021 5:10 am

Looks great! What sensor did you get?

Sun Feb 28, 2021 5:15 am

Odd_Dutch wrote: Looks great! What sensor did you get?

It is shown earlier in the thread, it is for a semi truck.
Page #1

Dave

Sun Feb 28, 2021 5:27 am

DanHoug wrote: wow! that solder/weld looks great!! it'll be just fine and is encouraging to see it so nicely flowed.

i've tried that stuff on an AC condenser and the solder just rolled around without sticking. i think it was AC oil contamination that kept oozing out confounding the process.

Thanks!
Everything I read said CLEAN!

If soiled degrease with brake clean and then wire brush or sand.

I had done a test awhile back on some aluminum scrap.

After I was done I tried to break the joint.
It didn't break, the aluminum next to the weld bent and when pushed the aluminum itself fatigued and broke.

Dave

Sun Feb 28, 2021 8:41 am

I have tried aluminum soldering and I still haven't gotten the hang of it. Great job, that looks really solid.

Sun Feb 28, 2021 10:07 am

Tank is in!

Modified the stock tank holder but I have an extra in case this is a failure!

It also uses the stock VW hoses, which is a surprise!
I didn't buy new hoses for here.

They both have been shortened, the lower one I cut off the 1” expanded portion.

And hey! The engine cover even latches! This is the first time the engine cover has been on since the Van left Philly!

In conclusion, I had fun.
It took way too much time and I spent darn near what GoWesty wants for theirs.

If I had a do over card? I'd probably buy GoWesty's.

Dave

Sat Mar 13, 2021 2:08 pm

The tank is mounted and works great!
Really happy with it.
I put a lever release cap on it.

The level sensor works, it turns on the light if low, turns it off if the tank is full.

Gotta say, despite the expense I really like this tank.
I might take back my earlier GoWesty comment......... I would do this tank again. It is slim and just hugs the back of the engine opening.

Dave

Sat Mar 13, 2021 2:35 pm

getting rid of that Blau cap (or worse imitators) is one of the best upgrades for these vans. the coolant reflux to the overflow tank becomes so much more reliable. not to mention the blow molded tank faults. well worth the cost!

Sat Mar 13, 2021 9:25 pm

I just finished installing a GW aluminum tank in a friend's 2.3 WBX Weekender. After two plastic reservoirs in less than four years, she decided the expense was worth it to protect that awesome RJE engine. I really like having the sight glass to use as a guide for refilling the system without lots of fiddling. I nailed it on the first try without having to fiddle or bleed anything. Would buy again.

Sun Mar 14, 2021 5:45 am

Zeitgeist 13 wrote: I just finished installing a GW aluminum tank in a friend's 2.3 WBX Weekender. After two plastic reservoirs in less than four years, she decided the expense was worth it to protect that awesome RJE engine. I really like having the sight glass to use as a guide for refilling the system without lots of fiddling. I nailed it on the first try without having to fiddle or bleed anything. Would buy again.

I'm quite surprised that you would endorse a non VW part so fervently!
You feeling OK?

Dave

Sun Mar 14, 2021 9:21 am

My personal van is full of non-VAG parts, but it has a VAG engine. You should be more weirded out that I'm endorsing a GW product.

Thu Apr 29, 2021 9:24 am

Just an update.

My tank is working absolutely fine.

I have a very small radiator seepage (I have a new Radiator, just not installed yet) so my coolant drops slightly.

I was anally checking it daily but decided to wait a few days.

The other day I took off and the blinky LED was winking at me.
It wasn't up to temp yet so I pulled over and sure enough the fluid had dropped below the level sensor probe.

So the tank works well and my Peterbilt coolant level sensor works well too.
I love the lever lock cap feature too!

All in all, a fun project that works well.

I am thinking of adding another bung in the lower part of the tank for a coolant temperature probe.
I know it isn't the prime place to get temperatures from but I think it is good enough, there is a heck of a lot of hot coolant flow through that tank!

Dave

Thu Apr 29, 2021 9:30 am

DJK
Having a tank made, what sensor did you go with? can you send me the info to obtain one.

Thu Apr 29, 2021 9:32 am

the joker wrote: DJK
Having a tank made, what sensor did you go with? can you send me the info to obtain one.

Go to the first page of this thread. Details are there.

Dave

Wed May 19, 2021 7:49 am

Dave, do you notice your overflow tank coolant level rising and falling while operating the van?

With my VanCafe unit I don't notice the overflow move at all. And the one time that I opened my cap just to check if it was low, because it doesn't have a sight glass, coolant spilled everywhere. So it's probably full. But the overflow just doesn't move like it used to.

Wed May 19, 2021 12:18 pm

I've noticed no appreciable fluctuation in coolant levels.

My tank is however smaller than the RMW tank.

Dave

Tue Jun 15, 2021 9:02 am

Would these Ali Tanks work ok in a diesel engine, and if so any Uk sellers cos the postage abroad is killing me