It looks like the thermostat adapter is pinned to the original housing and sealed with JB Weld.

http://s46.photobucket.com/user/healey5 ... d.jpg.html

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2006 CRD Sport
GDE FT ECO tune, GDE TCM ECO tune, ARP studs, HDS-001 203F T-Stat, 3.7L nylon fan & Hayden 2905 clutch, Carter P76148M in-tank pump, Racor 245R122 filter head & 2 micron R25S fuel filter, Provent 200, Samcos, Fumoto F-102, Litens 920834A de-coupler, PML rear diff cover, OEM trans pan with welded in bung, JBA UCAs, full skids.

Any updates OP? Still interested what thermostat you found to put in there.

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Interested

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2006 KJ CRD Ltd - Suncoast, GDE Eco, EGR Delete, After market T-Stat, Skid Row skids, V6 airbox, 2.5" Turbo back
2005 KJ CRD Sport-Suncoast, Transco, GDE Hot-GDE Trans, EGR Delete, Skid Row skids, V6 airbox, 2.5" Turbo back, After market S-Stat
1987 Suzuki LWB Samurai -diesel powered, custom 4 link coil suspension 38.5 SX Swampers

hi
waited to see how much interest there is as stated have used this in mine now for over a year with no problems so this is why i posted
it. all you need is moto rad 335-90 =192 or 335-180 =180degree I paid$12.00 each. jb weld and gasket I will supply boss tapped for your 1/4 fine studs and nuts and template to drill your top and 1/8 pins
This is strickly a labour of love I machine them one at a time for those interest please pm me
I am 50min from watertown ny where i can mail them I must have 10 units to make trip worth while price $50.00 +shipping est with my
fuel cost $10.00

I have the upper and lower casting secured with a modified V-Band clamp. Just waiting on a gates thermostat to see if it will drop in. r.

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06 LIMITED 100000miles, MAGNAFLOW, HOMEBUILT CCV FILTER, POLAR PAD, 02 AIRBOX, CUMMINS LIFT PUMP, SEGR, PILLAR GAUGE POD, CAT FILTER MONITOR, SPYDER TRAX, ALWAYS A LITTLE TWO STROKE OIL OR BIO, WATER/METH INJECTION

good thinking RJM... what size is it or manufacturers name and part number?

http://www.summitracing.com/parts/ppe-5 ... oCy2_w_wcB

If the thermostat that you have in mind woks, then the issue should be solved.

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2006 Liberty Limited CRD, Deep Beryl Green, Yeti tune, Arp studs, new cams, rockers, lifters, TB. "Green Monster"
2005 Liberty Sport CRD, Deep Beryl Green, GDE Hot Tune, ARP studs. "Rocket"
1982 Fiat 124 Spider Convertible. "Fiona"

Ah, I see, that's the same stat that Kap used.

Not too keen on the JB Weld but depending on the quality of the casting you may be able to weld the boss onto the lower housing.

Being able to reuse the OE outlet is key to keeping the overall cost down

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I've got a thermostat that's gone cold right on schedule, and I want to get this done. Are you still making the parts, or if not can you post dimensions so I can get a machinist to make them?

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The fuel savings from my engine modifications should pay for those modifications in about 250,000 miles

I went a slightly different route.
I separated the stock t stat housing and disposed of the thermostat thingy inside.
Then I sealed the housing back together with JBweld.
A Meziere aluminum thermostat housing holds a 195 deg t-stat in the upper radiator hose.

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U.S. Army Retired

without a thermostat in the housing, you have an open port from the lower rad hose to the inlet...that doesn't present a problem? Seems like it might...

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The fuel savings from my engine modifications should pay for those modifications in about 250,000 miles

Yes, the lower outlet port in the thermostat housing (bypass) is left wide open.
I've got at least 6000 miles on my setup and it worked great all through summer. Actually ran a little bit cooler than I expected.

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U.S. Army Retired