WWDiesel wrote:
2. OEM thermostat housing gutted & valve removed. -- Until inline thermostat starts to open to allows flow to the radiator, all flow is directed through the bypass circuit and heater core circuit. But without a bypass valve in the circuit to control the flow, the flow through the bypass circuit is continuous regardless of the position of the inline thermostat valve. The coolant flow in this case will always take the path of least resistance,
and I fully suspect the bypass from the thermostat housing to the water pump suction would always be the path of least resistance....
So in this case, the inline thermostat may never see the true temperature of the coolant since so much of the flow is traveling the bypass circuit, but the head will certainly be exposed to it...
On this point I disagree.
Mainly because the outlet to the radiator is larger making it the path of least resistance.
But also because many older engines operated just fine without a valve to block the bypass.
Yes, I know, just because grandpa did it this way doesn't mean its the best way.
None the less...
Because I know cylinder head temp might be a concern, I added a temperature sensor to the head.
Its a cheap sensor, just stuck to the surface of the head between cylinders 3 and 4. But it has provided me some good data about cylinder head temperatures under a variety of operating conditions. And I chose that location for the sensor because it is farthest away from the thermostat outlet.
For example:
1. While cruising at about 65mph, 1900rpm, head temperature is on average 20 deg F cooler than coolant temperature. This has been consistent under a variety of conditions, both summer and winter.
2. After cruising at 65 and then coming to a stop, just idling, head temp will rise to within 1-5 deg F of coolant temp. Again, this has been very consistent, both summer and winter.
What those two things tell me is that at higher rpm there is greater coolant flow and that the coolant is doing its job pulling heat away from the aluminum head.
Then, while idling at a low rpm, there is less coolant flow and the head temp will become near equal to coolant temp. (let it idle long enough and the temperatures will equalize)
So I guess I am the test subject for this type of thermostat setup (gutted + inline) and if anything goes awry I will definitely report it.
Until then we can just agree to disagree
This pic was taken on a cool spring morning after a 20min drive to work and idling in the parking lot: