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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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Posted: Sat Feb 27, 2021 2:53 pm Post subject: Re: Alternative Aluminum coolant Expansion tank |
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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 _________________ Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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DanHoug Samba Member
Joined: December 05, 2016 Posts: 4715 Location: Bemidji, MN
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Posted: Sat Feb 27, 2021 5:56 pm Post subject: Re: Alternative Aluminum coolant Expansion tank |
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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. _________________ -dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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Odd_Dutch Samba Member
Joined: March 20, 2011 Posts: 82 Location: The Hague, Netherlands
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Posted: Sun Feb 28, 2021 5:10 am Post subject: Re: Alternative Aluminum coolant Expansion tank |
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Looks great! What sensor did you get? _________________ 1980 2.0L Tintop - Subaru EJ-20 conversion |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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4Gears4Tires Samba Member
Joined: October 08, 2018 Posts: 2982 Location: MD
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Posted: Sun Feb 28, 2021 8:41 am Post subject: Re: Alternative Aluminum coolant Expansion tank |
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I have tried aluminum soldering and I still haven't gotten the hang of it. Great job, that looks really solid. _________________ '87 Syncro
Ferric Oxyhydroxide Superleggera Edition |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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DanHoug Samba Member
Joined: December 05, 2016 Posts: 4715 Location: Bemidji, MN
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Posted: Sat Mar 13, 2021 2:35 pm Post subject: Re: Alternative Aluminum coolant Expansion tank |
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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! _________________ -dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12103 Location: Port Manteau
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Posted: Sat Mar 13, 2021 9:25 pm Post subject: Re: Alternative Aluminum coolant Expansion tank |
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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. _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12103 Location: Port Manteau
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Posted: Sun Mar 14, 2021 9:21 am Post subject: Re: Alternative Aluminum coolant Expansion tank |
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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. _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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Posted: Thu Apr 29, 2021 9:24 am Post subject: Re: Alternative Aluminum coolant Expansion tank |
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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 _________________ Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert
Last edited by djkeev on Thu Apr 29, 2021 9:33 am; edited 1 time in total |
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the joker Samba Member
Joined: October 12, 2006 Posts: 1287
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Posted: Thu Apr 29, 2021 9:30 am Post subject: Re: Alternative Aluminum coolant Expansion tank |
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DJK
Having a tank made, what sensor did you go with? can you send me the info to obtain one. |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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4Gears4Tires Samba Member
Joined: October 08, 2018 Posts: 2982 Location: MD
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Posted: Wed May 19, 2021 7:49 am Post subject: Re: Alternative Aluminum coolant Expansion tank |
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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. _________________ '87 Syncro
Ferric Oxyhydroxide Superleggera Edition |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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steveo9007 Samba Member
Joined: April 22, 2021 Posts: 31 Location: Cornwall, UK
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Posted: Tue Jun 15, 2021 9:02 am Post subject: Re: Alternative Aluminum coolant Expansion tank |
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Would these Ali Tanks work ok in a diesel engine, and if so any Uk sellers cos the postage abroad is killing me _________________ 85 Autosleeper KY Engine, ALD Box |
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