mounting intake thermosensor in thin wall pipe
 

How would you guys mount a 3/8 NPT threaded thermosensor in thin-wall SS intercooler pipe?

Depending upon how thin...

ghetto version (but still potentially effective) is to drill and tap the pipe and JB weld the crap out of the whole assembly

probably the better way to do it would be to drill the spot and weld a NPT threaded nut or spacer over the hole.

Not sure if you are doing a pre/post IC measurement, but if for IATs, why not drill and tap the intake manifold?

mcmaster sells threaded bungs... 4464K223 is what you want.

+1 weld a sensor bung or nut into the pipe. Do you have a GM sensor? I think it's a 3/8" NPT. But that's memory so double check first.

A variation of the above: drill for a brass NPT bushing, like this one:

Brass 1/2" to 3/8" NPT hex bushing

JB Weld that into the pipe, then you can install/remove the IAT sensor. Only downside is that a 1/2" NPT tap is probably 2-3x as much as the fitting itself. :( I'd weld one in, as suggested above.

Cheers!

Jeff

i just drilled and tapped it my intercooler pipe, it's like 1 thread but it's tight and i put silicone sealant around the threads, works fine

Welding the 3/8" npt bung is the correct way to do it.

Yep.

Here's another easier ghetto way to do it. Punch a smaller hole through an IC hose coupler where you want it mounted. Put a washer on both sides of the thermosensor sandwiching the hose. Nut the threaded side of the thermosensor. The hose coupler with washers on both sides will form a gasket that won't leak. I used this method for mounting a alky injection nozzle on my FXT. Didn't leak at 24 psi.

Frank

If the washer or nut falls off it'll get sucked into the engine....

I JB-welded it. I'm screwed if the sensor ever fails, or I want to change my IC piping, but it works.

The hose acts as a gasket and a lock washer as it pushes against the nut. Use some teflon tape on the threads or loctite and it ain't going anywhere.

Do you want a permanent install to trigger something or always log, or something to just test temps and then possibly remove it? It's easy to swap out a coulpling after you're done testing/logging.

Frank

yea drill, jb weld, done

mines been fine for 4+ years

robo, what the dilio my friend

Weld (JB or Tig, your choice) a female 3/8 NPT fitting onto the outside of the pipe with a hole for your sensor to peek through. Screw sensor in with loctite, done.

Alternatively, you could get a 1/2 to 3/8 adaptor (1/2npt male outside, 3/8 NPT female inside) and thread it into the tube, weld it in place airtight and then thread your sensor into that.

nm man, finishing school

and trying to make this damn car faster lol

i hear that, ditching any parts soon?