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OEM Thermostat Inserts
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=5&t=85668		 Page 1 of 1
Author:  APC9199 [ Tue Nov 29, 2016 12:13 pm ]
Post subject:  OEM Thermostat Inserts
Does anyone know if the INSERT for our thermostats can be purchased by itself? I have a feeling the answer is no, otherwise the thermostat modification (which I am currently doing) would probably have used them instead of the stant or equivalent inserts. I have access to a full machine shop with welders, etc so I am trying to accomplish the most OEM look and function possible. Rather than weld two large machined plates onto each half of the separated thermostat housing, I wanted to weld a few tabs around the OD of the unit and use 3 screws to hold it together, then just have an o-ring groove machined into the inside face so it seals when screwed together. The only problem is finding a replacement for the thermostat itself.

I have seen plastic thermostat housings on amazon, etc, that have similar looking thermostats preinstalled in them, but don't see a place to buy the thermostat itself. If anyone knows, please share the wealth. If I can make this work I'll make my plans available as others have in the past with their projects.

Thanks!
Author:  flash7210 [ Tue Nov 29, 2016 1:01 pm ]
Post subject:  Re: OEM Thermostat Inserts
I know of no such thing.
If you find something that looks similar you could try it to find out.
Looks like Gates might have something http://www.gates.com/products/automotive/passenger-car-and-light-truck/cooling-system/integrated-thermostat-housings/standard-integrated-thermostat-housing
Maybe try contacting them.
Author:  WWDiesel [ Tue Nov 29, 2016 2:05 pm ]
Post subject:  Re: OEM Thermostat Inserts
APC9199 wrote:
Does anyone know if the INSERT for our thermostats can be purchased by itself? I have a feeling the answer is no, otherwise the thermostat modification (which I am currently doing) would probably have used them instead of the stant or equivalent inserts. I have access to a full machine shop with welders, etc so I am trying to accomplish the most OEM look and function possible. Rather than weld two large machined plates onto each half of the separated thermostat housing, I wanted to weld a few tabs around the OD of the unit and use 3 screws to hold it together, then just have an o-ring groove machined into the inside face so it seals when screwed together. The only problem is finding a replacement for the thermostat itself.

I have seen plastic thermostat housings on amazon, etc, that have similar looking thermostats preinstalled in them, but don't see a place to buy the thermostat itself. If anyone knows, please share the wealth. If I can make this work I'll make my plans available as others have in the past with their projects.

Thanks!

If you have not read this thread, please do so, it will give you a lot of insight to what has been tried and was successful in the past... :wink:
viewtopic.php?f=169&t=50940

Right now, Kaps engineered modification to a stock OEM thermostat housing is the only viable and cost effective solution other than replacing with a new OEM unit...
TDF has a new whole housing unit for sale, but some feel it is a bit pricey, it is extremely high... :cry:
Picture:> http://i63.photobucket.com/albums/h125/ ... 3hpscu.jpg
Author:  Ceearedeedriver [ Tue Nov 29, 2016 2:23 pm ]
Post subject:  Re: OEM Thermostat Inserts
APC9199 wrote:
...I wanted to weld a few tabs around the OD of the unit and use 3 screws to hold it together, then just have an o-ring groove machined into the inside face so it seals when screwed together.

Sounds like you haven't taken one apart? There's already an O-ring in there to provide a watertight seal between the two halves. The crimp is just to mechanically secure the two halves together. There's not much clearance so you'd have to be careful with the size and location of the tabs.

Your minimalist idea is certainly viable if you can pick up the thermostat element but this is going to be tough to source and it's unlikely to be cheap, available off the shelf in one-off quantities, or available in a selection of opening temperatures.

If you simply want to duplicate the OE thermostat look, feel and functionality why not just buy an OE thermostat?

If you wish to DIY and make use of the facilities you have available there are a couple of perfectly good DIY options available that a number of us are using. Kap above and Sarge viewtopic.php?f=5&t=84571

I've had Sarge's mod running in mine since May. It's real easy to do,
Author:  SargeIndustries [ Tue Nov 29, 2016 3:52 pm ]
Post subject:  Re: OEM Thermostat Inserts
APC9199 wrote:
Does anyone know if the INSERT for our thermostats can be purchased by itself? I have a feeling the answer is no, otherwise the thermostat modification (which I am currently doing) would probably have used them instead of the stant or equivalent inserts. I have access to a full machine shop with welders, etc so I am trying to accomplish the most OEM look and function possible. Rather than weld two large machined plates onto each half of the separated thermostat housing, I wanted to weld a few tabs around the OD of the unit and use 3 screws to hold it together, then just have an o-ring groove machined into the inside face so it seals when screwed together. The only problem is finding a replacement for the thermostat itself.

I have seen plastic thermostat housings on amazon, etc, that have similar looking thermostats preinstalled in them, but don't see a place to buy the thermostat itself. If anyone knows, please share the wealth. If I can make this work I'll make my plans available as others have in the past with their projects.

Thanks!



I tried contacting Behr(Manufacture name on stock thermostat housing) years ago to see if I could buy just the inside thermostat. They would not sell it by itself. Feel free to try, maybe you will get someone more helpful on the phone.
Author:  APC9199 [ Tue Nov 29, 2016 5:24 pm ]
Post subject:  Re: OEM Thermostat Inserts
Ceearedeedriver wrote:
APC9199 wrote:
...I wanted to weld a few tabs around the OD of the unit and use 3 screws to hold it together, then just have an o-ring groove machined into the inside face so it seals when screwed together.

Sounds like you haven't taken one apart? There's already an O-ring in there to provide a watertight seal between the two halves. The crimp is just to mechanically secure the two halves together. There's not much clearance so you'd have to be careful with the size and location of the tabs.

Your minimalist idea is certainly viable if you can pick up the thermostat element but this is going to be tough to source and it's unlikely to be cheap, available off the shelf in one-off quantities, or available in a selection of opening temperatures.

If you simply want to duplicate the OE thermostat look, feel and functionality why not just buy an OE thermostat?

If you wish to DIY and make use of the facilities you have available there are a couple of perfectly good DIY options available that a number of us are using. Kap above and Sarge viewtopic.php?f=5&t=84571

I've had Sarge's mod running in mine since May. It's real easy to do,


I have reviewed as much information on the available options as I could find. I understand that Kap's mod is the most viable option for people who can't/won't pay for the HDS-001 and people who refuse to pay the price for a sub-standard OEM unit. I was simply researching other options. It sounds like there is not a source for individual thermostats which I am not surprised to find out. Someone with an interest un hundreds or maybe thousands of them could probably get an ear at Behr (or other) to listen to them, but surely none of us will.

I HAVE taken one apart and I do know that there is an o-ring groove inside it already. My issue is that grinding it apart and potentially welding a ring around that rim is going to damage/eliminate the groove. If I attempt to continue with my own design, I'll have to re-machine it into the housing after welding.

So, another question for people who have played with these more...what is the failure mode for for the insert itself? Do the springs fatigue and become weak? Is there something else I'm not seeing? I'm dumb AND stubborn enough to entertain the idea of making the insert itself repairable instead of replaceable, with a replacement spring or otherwise if possible. It appears the rivet in the end of the insert could be drilled out to get the springs off and possibly re-tapped to accept a screw.

Again, this is all just exploration for me. I might end up doing the tried-and-true modification and be done with it. haha!
Author:  Ceearedeedriver [ Tue Nov 29, 2016 7:14 pm ]
Post subject:  Re: OEM Thermostat Inserts
APC9199 wrote:
Do the springs fatigue and become weak? Is there something else I'm not seeing?

I'm sure there will be other opinions on this but my belief is that the failure is caused by coolant leaking into the wax bulb. There was quite a bit of coolant in there when I pulled the plunger out of mine.
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