192º Thermostat - Parts Diagram/dimensions added page 1

Roostre · **Joined:** Sun Oct 24, 2010 3:57 pm **Posts:** 195

How far down the list you gonna make it?

CRD Joe · **Posted:** Sun Apr 03, 2011 6:54 pm

Let us know when you want some cash.....

kapalczynski · **Posted:** Mon Apr 04, 2011 2:51 am

Roostre, all the cores that I have I will get done. Other than that I am not sure. Some of the cores I have will go to a couple of people on the list. So if it says core recieved by a name I will get that done for sure adn have a few other housings done for the next people on the list.

As mentioned, I don't want $ untill I am finished with the housings.

Also, Kia finally fulfilled my order with them. I have 25 brand new water outlet housings now

Happy they caught up to my order. ha ha

Lately I've been helping my neighbor that just got back from Iraq with his jeep doing u joints, etc, etc, etc(its a jeep), etc and a few other friends are cashing in on my free labor to get their cars up to par so I've been doing brakes, etc. ha ha. Thats the way of things. I've also been doing a little work on my grand cherokee. Fixed the passenger heated seat and replaced a power seat motor to get it ready to sell. I sold my 07 charger, and bought a little daily driver 2004 saturn Ion 2 coupe w/ suacide doors and 130k miles on it for $3400 (1k under book due to a wheel bearing noise and some minor hail damage) and have been doing a little work on it. I plan to finish the thermostat housings I have, haul lathe, tools, household stuff to a storage unit, then sell my jeep and trailer in that order. Then sell the house. The saturn I will drive for 4-6 months and take to texas for a training trip and back then sell it right before I leave for Australia.

Just thought I'd give you guys a little update. As soon as I am caught up with the few things on the saturn (I want to do spark plugs and a thermostat - already did wheel bearing) I will get back on the thermostat housings.

I'll keep you all posted as I go. I think most of you have my cell number, if not adn you want to chat, you can shoot me a PM and I'll send you my number in case you want an update on the spot.

- Mark

Phatjimmy · **Posted:** Mon Apr 11, 2011 10:12 am

Hey guys,

This list is still showing "closed". Is anybody taking this project over from Mark? I have a spare core and if I can get a redesigned thermostat made, I'll have the one currently installed on my CRD as a core as well. If you can, let me/us know who is taking this project over. I tried to read through all 31 pages of this post for the alternate machining guru but didn't see it. I may of missed it though. I would love to get my hands on one of these if anybody has a spare redesigned thermostat??

kapalczynski · **Posted:** Thu Apr 14, 2011 4:35 pm

Roostre has plans to try and take on the project. He has alot of machine experience and I think will do a great job. As of this point I am hoping to get a kit of sorts together to send him so he has everything i did to do the project such as the pressure test equipment, some example parts to measure from, schematics, etc. I'm not sure how deep into the project and how much of a full time project he is going to want to get in to this, but that will all get figured out eventually.

As of today I have 26 cores (not sure how i got an extra one. lol) that I am working on. I've been working hard at this project today and I have 26 of them all cut open and the thermostats removed and of the 26 i have 12 machined flat. I am going to keep at it and hopefully get them all done before I have to leave for Australia.

Nelson 15's is pretty much done, but I need to machine one intermediate part that i thought I had on hand. At this time I will finish the milling since the machine is set up for it and when i get to the lathe part I will do nelson's first since i told him it was ready and mistakenly did not have that part.

I will be super busy on the project, but will check in and keep you all updated as much as i can. If i don;t reply super fast to emails or the thread it's cause I am so busy, but I promise i won't leave you guys hanging for tool long.

Gonna get back out to the garage,

- Mark

jinstall · **Posted:** Sat Apr 16, 2011 10:33 pm

darn I have to get this WO shipped out ot you, I forgot all about it. Please bug me about it weekly.

fastRob · **Posted:** Thu Apr 28, 2011 12:28 pm

Mark,
How is the project going?
I hope everyone is not calling you with updates.
The thought of going to Australia would be filling my mind for sure...
Rob

kapalczynski · **Posted:** Sun May 01, 2011 3:43 am

Things are progressing, not as fast as I'd like, but here and there getting things done. As of late I have been Craigslisting a TON of stuff. Selling auto parts, furnature we dont need (stuff that was given to us and have since replaced, etc). We've had more people running through our house in the last week than we've probably ever had in the house at all. been a very busy week.

I've sold our 07 dodge charger R/T AWD Hemi and bought a cheap 04 hail damaged saturn I paid cash for to give us something to drive so I can sell my jeep. My thoughts on this are the saturn will be easy to sell fast and the Jeep will take some time since it has a huge lift, etc. Also gives us something cheap/economical to drive in the mean time.

Right now, I'd love to take time off work, but we don't have the personnell to cover thing to allow me to take time off.

I still have high hopes of getting this all finished, I'll update you as I get more done.

- Mark

kapalczynski · **Posted:** Sun May 01, 2011 3:45 am

jinstall wrote:

darn I have to get this WO shipped out ot you, I forgot all about it. Please bug me about it weekly.

If you have a thermostat core, perhaps talk to Roostre about shipping it to him? He's going to be taking this project over if all goes well for that.

- Mark

dgeist · **Posted:** Sun May 01, 2011 7:45 am

kapalczynski wrote:

My thoughts on this are the saturn will be easy to sell fast and the Jeep will take some time since it has a huge lift, etc. Also gives us something cheap/economical to drive in the mean time.

Right now, I'd love to take time off work, but we don't have the personnell to cover thing to allow me to take time off.

I still have high hopes of getting this all finished, I'll update you as I get more done.

- Mark

We're all rooting for ya, Mark. Just think, if you can get all the t-stats out the door and recoup your out of pocket expenses so-far from all of us paying, it'll be about the same cost as the beater saturn

Greasey Bob · **Joined:** Tue Dec 14, 2010 3:34 am **Posts:** 228

Is it unfair to ask for the design, so I can build one myself without having to start for scratch. I can see the Kia/Hyundai thermostat cover and the 350 chevy thermostat, I think that was the most common use of 192 thermostat.

geordi · **Posted:** Mon May 02, 2011 1:22 am

I'm sure Mark would provide that to you... But he also has a LOT of R&D knowledge in this, and custom machining on each and every unit that is needed to make the design work.

Do you have a machine shop available, including a lathe and shop press? Roostre is going to be taking this over (if all goes well) so we won't be left alone out there when Mark moves into this promotion.

Roostre · **Joined:** Sun Oct 24, 2010 3:57 pm **Posts:** 195

I'm eagerly awaiting Mark's package in the mail.

Geordi hit the nail on the head. Mark has done the work and he owns the intellectual property involved here. I'm sure that with some trial and error it could be figured out, but I prefer to defer to Mark's knowledge on this. My plan is to figure out a way to kick part of the proceeds back to Mark in Australia... maybe via Paypal. May not be much, but perhaps he could take his bride out for dinner on the CRD bunch. :wink:

I have actually PM'd him about offering the plans online as an alternative to passing this off to me (or anyone else). It would require some good drawings and instructions, but he is already doing that either way.

taroo · **Joined:** Sun Apr 27, 2008 2:14 pm **Posts:** 292

So, does anyone know where the cutoff is on the list that Mark is working off of? This is a great initiative and Mark deserves kudos.

dgeist · **Posted:** Mon May 02, 2011 7:40 pm

taroo wrote:

So, does anyone know where the cutoff is on the list that Mark is working off of? This is a great initiative and Mark deserves kudos.

Page 1, post 1.

Dan

Greasey Bob · **Joined:** Tue Dec 14, 2010 3:34 am **Posts:** 228

I would love to do it myself since I am not going to be getting one in the mail. But I would rather not replicate work that has already been done. I can see the Kia part as a good choice and the 350 chevy thermostat also. but the machined parts would be much easier with a little help.

kapalczynski · **Posted:** Sat May 14, 2011 6:06 am

Greasey Bob wrote:

I would love to do it myself since I am not going to be getting one in the mail. But I would rather not replicate work that has already been done. I can see the Kia part as a good choice and the 350 chevy thermostat also. but the machined parts would be much easier with a little help.

Thermostat housing is kia sephia 1.8L, radiator hose is from 97 dodge intrepid (cut to fit), thermostat is from hyundai elantra 1.5L. As mentioned the units are not all exactly the same, there are some casting differences and deapth differences where the top piece is inserted into the main part of the unit and roll crimped. If you have access to the machine tools and a press you should be able to do it yourself. I would recommend a second unit so you don;t have your vehicle down for an extended period of time. Stud height depends on how deep you drill the holes you tap for them, spacer that gets pressed in depends on the deapth you machine the main flat area above. Basically you want the bypass port to be blocked off when the thermostat is open. The spacer that gets pressed in needs to complete this block off. Diameter of the space depends on how long the spacer is at the bottom and the individual casting diameter where it makes contact. It's all a give and take process. The key to the unit is the water outlet, finding the right radiator hose and the proper thermostat to work. Everything else you can figure out based on how you machine your unit.

kapalczynski · **Posted:** Sat May 14, 2011 6:26 am

Just another update, still far from done with all the units and leaving tuesday for training in Texas. I'll be there for about 2 months. House is almost ready for sale. Got the carpets cleaned yesterday, paint is touched up on walls. We still need to do interior trim and exterior trim touchups, move some things to storage, clean house inside/mow and trim lawn last time before we leave, saturn oil change, and meet w/ relator to sign papers to put house on market. House goes on market tuesday this week when we leave for texas. Hopefully house will sell about the time I come back and close a couple months later so I have time to finish these projects up. Fingers crossed. God only knows how the timing will work out. It appears I should be ablet o use my lathe/mill in Australia w/o too many issues.

If worst case scenario happens and house sells and I have to close before I get these finished, I'm not 100% sure if I will end up taking everything to Australia and finishing them up and shipping to states or just shipping what I have where I left off to Roostre. Nelson15 sent me a check awhile back, if i don't get you your unit out before i leave the states, I'll refund your $ untill we figure out whe i can get your unit. Its basically done (from last batch) but needs the intermediate plate (i was short one plate last batch and didn't notice) adn assembly. I'll try to get it done before i leave, we'll see.

My report date is 10 october for Australia, but we may end up leaving up to 2 months early (but not before that) if the house is sold.

All in all we are crazy busy trying to get house all clean/ready to sell before relator comes for photo's on Monday. Originally i was planning on taking 2weeks leave for time off to work on house and thermostats, but it was denied due to shortage of people to cover my shift at work

We've never had that problem, but had several people leave at once and are short handed. As it is I only got 2 days for time off so we are in a rush.

I'll do my best to not let anyone down and I will ensure I take care of you all (send cores to roostre if that is needed, refund's/return cores if necessary, I will keep in touch)

I'll check in often while in Texas, we're bringing our laptop and will have internet and my cell phone.

- Mark

Sir Sam · **Posted:** Sat May 14, 2011 2:57 pm

kapalczynski wrote:

It appears I should be ablet o use my lathe/mill in Australia w/o too many issues.

Well if something happens my offer still stands. :SOMBRERO:

Greasey Bob · **Joined:** Tue Dec 14, 2010 3:34 am **Posts:** 228

I got the housing out of the junk yard off of a kia. Looks just like the picture. But I was searching online for the thermostat and I could not find a listing for an Elantra with a 1.5L. Maybe it was and excell or an accent. Maybe you have the year for that?
I now have a second thermostat. I think I was waiting to install at the same time as the timing belt. but I might do it on the next free day off I have. Then I can cut up the one that is in my Jeep.

192º Thermostat - Parts Diagram/dimensions added page 1

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