192º Thermostat - Parts Diagram/dimensions added page 1

kapalczynski · **Posted:** Thu Aug 12, 2010 9:14 pm

geordi wrote:

Mark... You are 31 flavors of AWESOME for this. Tell ya what, if you ever get down to the Savannah area, drinks are on me. :5SHOTS:

As for cores, how's this for a deal - You send out one, you get 2 back from me, since I won't need the spare anymore. :mrgreen:

Hey, did you ever get on the list for one of these?!?!? You do want one right? I was going through all of my PM's and updating my list...I didn't see you on there. I could have swore you were one of the first but can't find it. If you do want one and maybe I missed your request(was it on a forum post?) please let me know. I know you have been following this since the beginning. I go by date anyway so if I missed a post somewhere back there where you wanted to be on the list let me know what page, etc and date so I can get you in the right spot.

For everyone else that may be interested, PLEASE PM me and formerly request it so I make sure I have you on the list in the right spot. It's better to be on the list holding a spot because I can tell now that these are going to take awhile each batch. Taking much more time than I expected.

- Mark

kapalczynski · **Posted:** Thu Aug 12, 2010 9:18 pm

Here is what I have for the waiting list and dates requested so far according to PM's:

tdiwyse - apr 1
forenic - apr 1
stoutdog - apr 4
squeeto - apr 4
nelson15 - apr27
bugnout - apr27
dgeist - apr27
catcrd (2qty) - apr29
mikey1273 - may1
stoutdog's dad(Jim) - may9
yakers - july14
fastrob - july31
kdlewis1975 - aug8

If you are not on here and should be please let me know so I can get you in the right spot.

- Mark

geordi · **Posted:** Fri Aug 13, 2010 11:28 am

I'm gonna go dig through the thread's earlier pages, I think I only requested one on that, rather than a PM. I'll shoot a PM with the info this time tho. It seems that my T-stat is finally starting to go, in the 98 degree summer of Savannah, and hauling around with a trailer on... I'm STILL solidly one line left of center.

Oh, and I noticed yesterday (while idling for a Loooooooong time on a film set with the AC blasting) that the electric fan wasn't turning. Goody, another problem to search down. At least it wasn't running anything at all warm while idling!

LibertyCRD · **Posted:** Fri Aug 13, 2010 11:39 am

I have a OEM t-stat (that failed) that is sitting in a box in my garage. I'm willing to donate it to science.

All I ask is that you pay shipping. If you'd like it.... PM me. kapalczynski, you use the old ones to make your version, right?

kapalczynski · **Posted:** Fri Aug 13, 2010 8:44 pm

Ok, geordi I found in march by a post. Also found forenic/forensic(same person) on a post in mar so I corrected those positions. Squeeto sent me a core specifically to reman for him so is kind of outside of the list since technically I only have 3 rolling cores and his is the 4th. I origonally forgot about that and was thinking I would have 4 units at a time, but it will be three for a normal batch.

If anyone of you have spare cores you can send I can do those w/the next batch, there is no limit on how many at a time I can do as long as i have the cores to reman. If any of you have extra cores please send them to me and I will pay your shipping. If you have 1 spare and 1 in vehicle, send spare to me and I will do it with my next batch, send it out and then you can send me your extra(i'll pay shipping) so we can up the quantities per batch and hopefully get this list done sooner.

So far I have geordi, forenic, tdiwyse for the first batch and have done squeeto's core on the side all which should be ready to send out soon.

**UPDATED LIST**

geordi - mar28
forenic - mar30
tdiwyse - apr 1
papaindigo - apr 4
squeeto - apr 4
nelson15 - apr27
bugnout - apr27
dgeist - apr27
catcrd (2qty) - apr29
mikey1273 - may1
stoutdog - may9
yakers - july14
fastrob - july31
kdlewis1975 - aug8
westfork - aug13

If you are not on here and should be please let me know so I can get you in the right spot.

If you requested by post, let me know right away and send me the link so I can get you on here. After this I will ONLY add people to the list by PM so I can keep an accurate list easier adn be fair to everyone.

- Mark

kapalczynski · **Posted:** Fri Aug 13, 2010 8:48 pm

LibertyCRD wrote:

I have a OEM t-stat (that failed) that is sitting in a box in my garage. I'm willing to donate it to science.

All I ask is that you pay shipping. If you'd like it.... PM me. kapalczynski, you use the old ones to make your version, right?

Yes, please send it!!! we need all the cores we can get.

LibertyCRD, if you are wanting one of my units, let me know and I will do it along side of my next batch, if not I will be happy to pay shipping to increase our batch size.

geordi · **Posted:** Fri Aug 13, 2010 8:55 pm

What was the final tally on the cost of these? Don't forget to put some in there for yourself, you are doing an awesome thing for the group, but there is no reason to be a saint about it.

kapalczynski · **Posted:** Fri Aug 13, 2010 8:57 pm

Also, just a reminder prices are $100 for my unit w/your core supplied, or $200 w/o a core and I will later refund $100 as soon as I get a core back. Also thermostats are around $10-$12 for an extra one, I will have to check recent prices. I think the 180 and the 190 are different prices also.

Another reminder, don't expect a fast turn around, these units take alot of time: The unit itself I cut appart/machine/drill/tap, a adapter peice I machine and press in, the studs I cut/install, the intermediate plate I machine/drill, and the custom gaskets i cut by hand. Although all of this takes alot of time (and I haven't had alot of that lately) I will do my best to get these done in a timely manner. Also, if anyone else out there has the time/capability to machine aluminum, I'd love the help and would be happy to share my design specs.

- Mark

kapalczynski · **Posted:** Fri Aug 13, 2010 9:01 pm

geordi wrote:

What was the final tally on the cost of these? Don't forget to put some in there for yourself, you are doing an awesome thing for the group, but there is no reason to be a saint about it.

Lol you posted while i was typing... Not much in that $100 for my labor due to the cost of metal stock, gasket material, thermostats, housings, etc bringing the cost up. I know I have ALOT more labor hours in these than anyone would want to pay for. Call it my love of the CRD that keeps me going.

CRD Joe · **Posted:** Sat Aug 14, 2010 1:32 pm

Please help me out here. What is the positive effect of this mod? Can I get in on it?

dgeist · **Posted:** Sat Aug 14, 2010 1:53 pm

CRD Joe wrote:

Please help me out here. What is the positive effect of this mod? Can I get in on it?

You get a serviceable thermostat assembly for roughly the cost of a replacement non-serviceable one, meaning NEXT time you need a thermostat (in a few years), it'll cost you $15 instead of $150.

Also, optionally, you can use the thermostat that's rated a little hotter, making the engine operate a bit closer to its ideal thermal efficiency numbers.

As you can see a few posts above, a personal message to the author will get you on the waiting list.

Dan

kapalczynski · **Posted:** Sat Aug 14, 2010 11:49 pm

Hey, papaindigo asked me some good questions in a PM about the upper radiator hose, etc. I thought I should share w/all of you the answer:

Quote:

The water outlet opening where the hose goes on and connects to opper radiator is a slightly different size than the factory outlet of the thermostat assembly. I found a hose from back of the parts room that is the perfect bend and fit for our application(I practically live behind the counter at all the parts stores in my area, they all know me and let me go thumb through boxes, etc to find my custom parts). I found the thermostats the same way. I also had the parts reverse directoried to give me vehicle applications. I wil include the list for everyone's convenience. Turns out the hose is from a dodge, the water outlet is from a kia (shouldn't ever have to replace that, unless you break the casting), the thermostats (both temps) are for a hyundai. I have all the part numbers and vehicle applications on a spreadsheet that I don't have handy right now, but will include them. So if you ever need a hose or a thermostat, you don't have to buy them through me. Hose and thermostat is usually in-stock at Autozone and Advanced auto, etc. I'm going to copy this and put it on the forum for all to read. Thanks for the good questions.

- Mark

Also thinking that it would save shipping costs to not ship the bulky hose and just share part numbers and vehicle applications for all the replaceable parts. I'm all about open source anyway.

I will get a list together, post it on here, and also put one in the shipped box. I will still include the thermostat installed in the unit and have the unit assembled and all torqued down and ready to install. I should probably figure out a safe torque spec for all of you for that too. Also, I think I mentioned before that I was going to figure out a way to pressure test the unit before shipping to ensure when tightened there would be no leaks from not being tight enough, etc.

Just my latest thoughts,

- Mark

audiboy86 · **Posted:** Sun Aug 15, 2010 1:28 am

Kinda getting in on this alittle late but why not use some test tube plugs made of high heat silicone. Fill the housing full of water with food coloring in it and put a hole in one of the plugs. Then put air pressure through it with a simple blow off/cleaning gun. I know in my engineering classes we use these same things in testing our micro hydralic designs.

kapalczynski · **Posted:** Sun Aug 15, 2010 1:56 am

audiboy86 wrote:

Kinda getting in on this alittle late but why not use some test tube plugs made of high heat silicone. Fill the housing full of water with food coloring in it and put a hole in one of the plugs. Then put air pressure through it with a simple blow off/cleaning gun. I know in my engineering classes we use these same things in testing our micro hydralic designs.

Thanks for the imput, this is what I was just thinking about after you jolted my brain in the right direction...

I can install a tire valve stem in a pvc end cap and clamp w/hoses. The temp sending unit port will get plugged w/teflon tape and a brass plug, the other ports (one of which is rectangle) might be more interesting...maybe a plate steel and a ruber gasket bolted on through the factory holes.

This way the pressure can be monitored and ensure it can hold PSI...also can put unit under water and look for air bubbles coming up.

So, pretty much just like what u were thinking, but backwards with air inside and looking for leaks under water.

Doesn't need to hold much pressure as the coolant is not pressurized much if at all.

Thx again for the imput.

Deeso · **Posted:** Sun Aug 15, 2010 9:38 am

We have a 16 psi cap on the coolant reservoir, so pressure testing to around 30-32 psi would seem adequate.

On the "clam shell" design that I have installed, one clam (housing) has an O-ring and the other clam has a flat face. When bolted together, the O-ring is the only seal and is working very well. I dont know if machining a groove on both sides of your spacer plate for O-rings would be easier / cheaper than hand cutting gaskets. Just a thought.

Dave

kapalczynski · **Posted:** Mon Aug 16, 2010 2:55 am

Deeso wrote:

We have a 16 psi cap on the coolant reservoir, so pressure testing to around 30-32 psi would seem adequate.

On the "clam shell" design that I have installed, one clam (housing) has an O-ring and the other clam has a flat face. When bolted together, the O-ring is the only seal and is working very well. I dont know if machining a groove on both sides of your spacer plate for O-rings would be easier / cheaper than hand cutting gaskets. Just a thought.

Dave

Good idea, if you saw the unit up close you would understand why I chose a gasket instead of o-ring seals.

Not much room for the o-ring as an important part that gets sealed is the very edge, about 1/16th of an inch from the edge actually. This is due to the machining process upsetting the original roll crimped seal around the edge and having to drill tap right through the old oring that is roll crimped in place between the 2 original parts. I use 1/8in thick buena n rubber material for gaskets that is extremely chemical and heat resistant and can also take the pressure of tightening down the nuts quite a bit to get a great seal. Material is not to expensive.

Here is a pic...see the thin line around the edge? that is where the two original parts were joined together with a rubber o-ring and then roll crimped around the edge to hold it in place. It is critical it is sealed because I found out early on that after machining that seal has less force on it (i machine some of the roll crimped aluminum away) and sometimes leaks. This gasket ensures no leaks whatsoever.

I bought a new exacto knife that turns as I change directions, makes the cutting easier so the last group of gaskets went well.

Deeso · **Posted:** Mon Aug 16, 2010 7:32 am

I should have known. You have a lot of time into the thought process and design let alone your time fabricating each piece. You do good work and is much apprieciated!

Dave

dgeist · **Posted:** Mon Sep 06, 2010 12:05 am

<Bump>

Trying to keep things on the first page, also, wondering if you'll have the chance to do any more of these before the cold fall weather starts to hit. Need to plan for the season when actual freezing takes place.

Dan

kapalczynski · **Posted:** Mon Sep 06, 2010 6:52 pm

Hey guys. Just wanted to pass on an update. Hoping to get back to work on these now. I just got back from Alaska Sat night. Hung out with the wife and had a date night.

We slept in Sun morining then I mowed the lawn, edged, fertalized, revived, applied bug killer and sprayed weeds. Today before work I washed our car for sale and detailed it. Finally getting all caught up so I will have some freetime coming up soon to work on the units.

I received 3 housings in the mail from you guys, haven't even checked the names on the boxes yet, but good to know I have more to work on after I finish this batch.

Hope to knock this first batch out soon...finally.

I'll let you all know when they ship out.

- Mark

**EDIT**

So far I have geordi, forenic, tdiwyse for the first batch and have done squeeto's core on the side all which should be ready to send out soon.

UPDATED REQUEST LIST
geordi - mar28
forenic - mar30
tdiwyse - apr 1
papaindigo - apr 4
squeeto - apr 4
nelson15 - apr27
bugnout - apr27
dgeist - apr27
catcrd (2qty) - apr29
mikey1273 - may1
stoutdog - may9
yakers - july14
fastrob - july31
kdlewis1975 - aug8
westfork - aug13
Gerge - aug16
CRD Joe - 19 Aug

If you are not on here and should be please let me know so I can get you in the right spot.

Remember I will ONLY add people to the list by PM so I can keep an accurate list easier and be fair to everyone.

Heres a list of cores I have recieved so far (remember you do not have to send a core first, it just speeds up production)

CORE RECIEVED LIST:
squeeto
LibertyCRD
bugnout
forenic

Thanks,

- Mark

fastRob · **Posted:** Mon Sep 06, 2010 9:30 pm

Does anyone have a core thermostat housing available?
I need to get one to Mark so he can do his thing.
When I pull my old thermostat housing I will send it to Mark for the next guy.
Is this too much to ask?
Would paying shipping be enough?

192º Thermostat - Parts Diagram/dimensions added page 1

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