What!?!
Don't tell me this. It was a pain in the azz to put that thing in there and I was proud as heck.
It's odd though because I searched everywhere and couldn't find it (hiding in plain sight) and someone in the forum actually suggested adding the valve.

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2005 CRD Limited:
* 245/70/16 Nokian Vatiiva
* Magnaflow
* Kennedy Diesel lift pump
* Custom CCV condensor
* Custom modified thermostat housing w/bleeder valve

2006 CRD Limited (wife's)
* Bone stock

Mark: Hope your trip went well. I know you have a few serviceable thermostat units in the pipeline. What's the queue look like currently? The weather here has been in the 80s and I still can't get the CRD up to operating temps with the AC on in rush-hour traffic... I feel like I'm flushing money down the radiator with poor economy (running around 20 presently where it was up around 25-28 last fall).

Dan

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2005 Silver CRD Limited
245/75R16 GoodYear Duratracs
Fumoto drain | ProVent CCV Filter
Stanadyne FM100 filter | Cummins fuel pump
GDE Eco | SEGR | BoulderBars | FrankenLift | Frankenskids

Hey all, here's an update. I am off tomorrow and hopefully will get all the units I have machined and ready to go. I know one of our members is down right now and waiting on me so I will get that sent ASAP.

Also, I am currently investigating a better gasket design using neoprene with a Durometer hardness of 70. With the current fibrous paper gasket material (felpro recommended for water/fuel/oil) I have noticed on my test assembly that there is a crystalized orange substance around the seam of the gasket. This is occurring not just on the gasket I custom cut for my assembly out of the bulk gasket material, but also around the felpro designed gasket that matches the waterneck application. This material appears to be wicking slightly causing the antifreeze to crystalize around the edge of the gasket. It is virtually unnoticeable and there is no drips/leaks, just a orange color around the gasket edge. I was doing research and picked the brain of my mechanical engineer friend who recommended neoprene for a material. This is widely used in the marine world for fuel gaskets, etc. I believe this will be a better choice for our application and may even be reusable (depending on how long it is in there) which would be nice.

Like I previously said, I really want to put a good product out for you all (and me...lets not for get I use everything I make on my daily driver CRD ). I may be going overboard, but I want it reliable and maintenance free. I am keeping the cost at $100 plus shipping as before even with upgraded gaskets.

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

Hey Dan, thanks. Trip went well. I took our toyota down so my wife would have the jeep just in case it snowed while I was gone (snowed right after i was back...lol). I hit some SERIOUS rain for abut 3 hrs straight and was wishing I was in the jeep...lol Everything after that was nice. I took some vacation time and visited my mechanical engineer friend in houston while I was down there and made the 16hr drive straight back with good weather.

As far as the T-stats go, I currently have 5 people on the waiting list. Just need to finish the housings, collect payment from those on the list that are ready.

PM me and I will add you to the list if you haven't done so already (I have my list at home so forgive me if your already one it. ).

- Mark

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

The non-wicking gasket material sounds like a better solution anyway. Keep up the good research and we can all benefit in the long run.

Dan

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2005 Silver CRD Limited
245/75R16 GoodYear Duratracs
Fumoto drain | ProVent CCV Filter
Stanadyne FM100 filter | Cummins fuel pump
GDE Eco | SEGR | BoulderBars | FrankenLift | Frankenskids

Mark
PM sent.

Hey, just got out of the garage. I cut and removed the old T-stats from the cores. I will machine the surface of the housings tomorrow, and hopefully I will have time to drill/tap and install the studs as well. I have the felpro gasket material, but am waiting on the neoprene I ordered to test the new material. I will run it at least a few days on my test stat in my CRD prior to packaging with the final product. I want to ensure the neoprene is the best choice for sealing w/o any chance for leaks, etc.

- Mark

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

There may be better choices than neoprene.

The Material Selected Neoprene
Interacting with the Chemical Antifreeze
Has a Compatibility Level of C-Fair

Explanation of Footnotes
1. Satisfactory to 72°F (22° C)
2. Satisfactory to 120°F (48° C)

Ratings -- Chemical Effect
A = Excellent.
B = Good -- Minor Effect, slight corrosion
or discoloration.
C = Fair -- Moderate Effect, not recommended
for continuous use. Softening, loss of strength,
swelling may occur.
D = Severe Effect, not recommended for ANY use.
N/A = Information Not Available.

http://www.coleparmer.ca/techinfo/chemcomp.asp

Buna-N (Nitrile) is compatible and is usually reasonably priced and probably easier for you to get than say Viton which would also work well.

http://www.catpumps.com/pdfs/Catalogs/CHEM-COMP-GUIDE.pdf

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2006 Liberty CRD Limited

Provent @ 43,000 km
SEGR in progress
SAMCO Sport hoses @ 48500 km
Goodyear Wrangler Duratrac LT225/75R16

So which from the list below would you recommend...they all seem similar.

http://www.mcmaster.com/#buna-n-rubber/=6uwofc

Was thinking this one with the higher tensil strength and hardness (70).
http://www.mcmaster.com/#buna-n-rubber/=6uwpez

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

Hey, thanks for the website that has the ability to compare those.

I ordered some of the Buna-N which seems identical in temp and pressure qualities, but has the "excellent" resistance to antifreeze.

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

Interesting. According to Mid Atlantic Rubber Co. who is a supplier for my mechanical engineering friend's company, neoprene is "excellent" for glycol compatability. He sent me the 29 page document that compares different rubbers with hundreds of chemicals. I tend to lean towards his experience as well. Antifreeze is primarily Glycol and water. What gives??? Even on your site it recommends neoprene and glycol with a "A".

Here's the reference to antifreeze on wikepedia. It is glycol or methanol based (older formulas):
http://en.wikipedia.org/wiki/Antifreeze

The 29 page document is a PDF or I would post that as well.
*edit* I found it on their website:
http://www.midatlanticrubber.com/pdf/compatability.pdf

I think either neoprene or buna-n (commonly called nitril or NBR) would be fine. I am not sure where your website gets its information that "antifreeze" (and who knows what type it is referencing) is not compatabile when it lists, water, methanol, and glycolic acid as all compatible with neoprene?!? <---Weird

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

Ours is ethylene glycol based.
Maybe check your pdf for ethylene and neoprene compatibility.

edit: Sorry just noticed your link.
The pdf recommends nitrile but not the neoprene.

I believe that is an incorrect assumption. Ethylene is just not listed separately, insufficient data on that part of the chart. "Glycols" covers all types of glycols so neoprene is fine.

According to the other website ethylene glycol is good with neoprene:
http://www.coleparmer.ca/techinfo/chemcompresults.asp

The Material Selected Neoprene
Interacting with the Chemical Ethylene Glycol
Has a Compatibility Level of A-Excellent

Explanation of Footnotes
1. Satisfactory to 72°F (22° C)
2. Satisfactory to 120°F (48° C)

Ratings -- Chemical Effect
A = Excellent.
B = Good -- Minor Effect, slight corrosion
or discoloration.
C = Fair -- Moderate Effect, not recommended
for continuous use. Softening, loss of strength,
swelling may occur.
D = Severe Effect, not recommended for ANY use.
N/A = Information Not Available.

Like I said, the coleparmer.ca website's reference of "antifreeze" is probably just incorrect.

Unfortunately I cannot find any reference to the temperatures that we will be running around 200* F with the antifreeze. The mcmastercarr website that says they are good for our temp, but other sites list "dry temp" for neoprene and nitril o-rings and don't go into wet temp with the chemicals. So it will still be a guessing game unless we get more information.

All the same, I should see the neoprene in the mail today or tomorrow and I also ordered the nitril so...lol I guess I'll just have both around the garage. lol I don't think it matters, but I will use the nitril for the assemblies because its the same price and its on its way also. Can't hurt to have the neoprene around the house for other uses.

I'm pretty sure it will hold up just fine.

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

I used this link of yours:
http://www.midatlanticrubber.com/pdf/compatability.pdf

On page 10 it has ethylene by itself. I don't know if, in the coolant, it is mixed or chemically combined with the glycol, etc. But it is worth another look.

Yeah, like I said, it is just not listed there. It should have a rating if it is recommended or not:

LEGEND
A - RECOMMENDED
B - MINOR TO MODERATE EFFECT
C - MODERATE TO SEVERE
U - UNSATISFACTORY
BLANK - INSUFFICIENT DATA

Gotta look at the legend my friend.

On the other site it specifically lists ethylene glycol as "A" - "Excellent" with neoprene

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

Anyway...I gotta get back to machining. I got the necks cut off and t-stats removed on 4 cores, 2 of the 4 cores faced, 2 more to go, then drill/tap and install the studs on all 4. Then I need to cut 4 more intermediate plates....lots to do today. Gotta get ur jeep up and running for you squeeto - ASAP.

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)

Ahhh, I see what you say.
I am half way working through another project at the moment; saw the recommendation ("A") for nitrile and none (missing) for neoprene.

No rush.
The wife is happy that her Audi is back on the road.

Presuming you don't blow anything up with this first round of Kapalczynski tstats, you can count my father and I end for the next batch

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2006 Jeep Liberty CRD, Limited
GDE Eco Tune, GDE TCM Tune, Bauer 203* Tstat, Amsoil EaA 201 Filter, Clean MAP, Samco CAC Hoses, Magnaflow Muffler #12226.
New Mopar Fuel Filter, K&N Filterminder, Fumoto Oil Drain Valve
225/75R16 Hankook Dynapros

I have you on the list for # 3 so you should be in this first batch - if you are ready for it. I'll PM everyone on the list in order they contacted me and as I get the payments I'll send them out.

If you want to wait, there are 8 ppl total on the waiting list so I can come back to you.

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Previous-05 CRD KJ;Current-2010 Taurus SHO Twin Turbo (450HP), 2014 Subaru Forester Turbo (stock)