Coolant Spacer, Thermostat Cover, Water Pump Inlet Housing for AN Fittings
 

This is a general interest thread.

I am planning on using braided steel hose coolant and heater lines in my Locost build and am going to have a custom coolant spacer, thermostat cover and water pump inlet housing CNC machined that will include SAE ORB ports to accept AN hose fittings. To distribute the set-up costs a bit, I am curious to know if there is any interest for these parts so that I can have them made at small quantity prices instead of at one-off prices.

The first part is the coolant reroute spacer. It includes ports for an OEM temperature sensor, an aftermarket temperature senor with 1/8"-27 NPT threads (specifically VDO part number 323-095) and a -10 ORB heater line fitting. The -10 ORB port will also accept a -10 to 5/8" hose barb adapter fitting, and the spacer will work with a Kia thermostat housing. The cost for the spacer based on an initial quantity of 5 is $75 each.

The second part is the thermostat cover. It includes a -12 ORB port designed to accept a 3" long -16 AN adapter (CSR Performance Products part number 9902L) for the coolant return line. The thermostat cover is designed to orient the port to the cold side of the engine. The thermostat cover extends back behind the engine the same distance as a Kia housing with 1-1/4" ID hose. I am still waiting for pricing on this part.

The third part is the water pump inlet housing. It includes ports for a -16 ORB coolant feed line fitting, a -10 ORB heater line fitting and a -4 ORB turbo coolant line fitting. The -16 ORB port faces the driver side, the -10 ORB port faces rearward and the -4 ORB port faces forward. I am still waiting for pricing on this part.

Renderings of the parts are provided below. Lead time is 5-6 weeks and I plan on ordering these parts as soon as I finalize the designs in the next month or two. Anyone interested please feel free to PM me.

I would be interested in all 3 parts. let me know pricing.

Id be interested in all 3 as well

Interested, but that second/third part look very expensive to CNC as designed. Let me know when you have a quote on the fab.

I revised the design of the water pump inlet housing. It should be less expensive to machine and now has a second -4 ORB port.

Thinking of the 3.

Though a few concern's:
-I haz no turbo, so i dont need the turbo bits (maybe save money by not tapping it?)
-I am unfamiliar with AN stuff, will AN stuff cross reference with the 5/8ths heater hose and not like my pcv hose which needed to be 10mm, but the parts store only has 3/8ths and that is 9.5mm which is .5mm too tight. (annoying the f out of me!!)
-maybe you can leave the holes untapp'd and I'll do it at home.
-ON #1 part you can put another 1/8th NPT hole for another sensor at about 70-80 degrees.

2. How about a block off plate for the front?

Thanks

You can plug one of the -4 ORB ports with a plug like this one:Aeroquip FCM3724 Aeroquip Plug Fittings - Free Shipping on All Orders @ JEGS. The other -4 ORB port is for a 5/16" (8mm) hose barb for the water line coming from the oil cooler and through the IAC valve. The cost of tapping the -4 ORB ports is negligible.

AN -10 fittings are used with 5/8" ID hose. More information is available here: http://aeromotiveinc.com/2010/01/an-vs-npt/

If it's for a temperature sensor, it will probably interfere with the thermostat unless I add another boss (which I would prefer not to).

This is already available from Trackspeed Engineering and BEGi.

Trackspeed Engineering
BEGi Miata Front Thermostat Block Off Plate

Just out of curiousity... Any willingness to allow your drawings to be open source? ;) I have a CNC here at work, and would like to make my own... :)

Hey SKOU, it seems like you made the blue print to a coolant spacer donut a few yrs ago. How much would one of those run me?

Sorry, but I'm not planning on having one of those made. You can get essentially the same design from BEGi for $93 plus shipping.

All of the good bits show up after I've already bought what was the good bits! Not fair. $75 for your better solution spacer, versus $93 I spent with BEGI.... :/

And I second nperkins question. Would you make these files available after your production run? These look very well designed, and I also know some people who work at a CNC shop.

I would be interested in all three parts. I too am building a locost.

Still waiting on quotes to come back. Attached are renderings of the final design of the thermostat cover. It now has a 3/4"-14 NPT port for this little guy.

https://www.miataturbo.net/attachmen...1&d=1386273413

OK, so based on 5 sets of 3 pieces:

Thermostat Spacer: $75 each
Thermostat Cover: $80 each
Water Pump Inlet Housing: $80 each

Anyone who is serious about buying these, please PM me so that we can work out payment details. Thanks.

How difficult/expensive is it to get plugs for the unused ports?

I'll buy yours for 75.

Cheap as heck. At least the NPT stuff is under 3 bucks a piece. There should be an carquest autoparts near belmont. And they should have about 200 fittings in stock.

I'm going to have to order all of the small bits for mine anyway and can put together a "hardware" package with fasteners, gaskets and fittings. Including port plugs is no problem. A brass 1/8"-27 NPT plug is about $2 and an aluminum -4 ORB plug is about $4.

packs of npt plugs on rockauto are 57cent each when you buy 5. Thought I would help. Still thinking about the spacer. How close are you to submitting the order? Also would prefer 3/8ths npt. And for two 3/8ths sending units.

To be fair, the BEGi spacer comes with the adapter for the heater hose, two pipe plugs, and both long bolts at that price. Although BEGi marks up the shipping and handling more than they should.

I want the parts.
Timing does suck as I can't justify spending close to $250 right now. When do you need to have payment? Could you take a deposit, maybe?

I think you should start a group buy thread of some sorts.


edit: also, why are you using ORB fittings? Are they cheaper to machine? I was under impression that ORB fittings cost more?

ORB - probably because o-rings are awesome.

--Ferdi

Ha! I was just thinking of doing something like this myself, as my recently-purchased CNC machine will be here later this month. (Heh, a CNC all to myself, this is going to get crazy).

I would be interested in this "group buy", probably for all 3 parts. Keep me updated.

^^^ That. No chingering up NPT threads after multiple installations and removals. Simple O-ring replacement if it leaks, tighten until snug, because threads aren't doing the sealing. Soviet is right, timing on this is bad. I want one of the water pump inlets, but Christmas.

Why did you decide to go back to NPT for the thermo cover, though?

Edit: Ninja'd.

Why ORB ports? O-rings provide a more reliable seal than tapered threads with sealant, but that's not really an issue for a low pressure application like this one. I'm using them because there's a larger selection as far as fittings from ORB to AN.

I went to an NPT port on the thermostat cover after talking to CSR Performance Products and finding out the threads on the port end of their 9902L adapter are actually 1-1/4” and not 1-1/16”. I could make the thermostat cover taller to accommodate the larger diameter, but the concern is that the thermostat cover and hose end will end up too close to the firewall. If someone could actually measure the clearance between the round water header on the back of the cylinder head and the firewall, it would be helpful.

Yeah, I guess my timing sucks. I’m open to taking deposits and fronting the cost for a few months. I really just want to be assured that there’s enough serious interest to justify moving forward with this.

Skou,

I can get you the total height of the BEGI spacer + Kia Water outlet if that would help. By round water header, do you mean the aluminum press-in fitting that goes to the oil cooler?

Also, here are some pics showing clearance from the BEGI+Kia to the firewall.

Sorta-easy Coolant Reroute – part 2 — revlimiter.net

Thanks, that would be helpful. This is the distance that I am after.

https://www.miataturbo.net/attachmen...6&d=1386371417

The Begi spacer + Kia neck is ~2.75" tall without gaskets. I tried seeing if I could wedge something behind that water piece, but with my coils and stuff in the way I couldn't.

Judging from that photo, you might have a total height of 3" to the firewall, but the Begi piece is already supposed to be near impossible to install with the engine in the car.

Anyone know how one would run a hose from the AN fitting to the standard pipe on the stock radiator?

Easiest solution is this...Meziere WA16125S Meziere Water Pump Fitting

You can also weld AN fittings into the radiator (assuming you meant "aftermarket aluminum" and not "stock")

I never thought to ask, but I take it -16 is fine for this for us? I know on larger engines they don't want to go below -20, but the price of -20 fittings and hose is WOW. MUCH HOSE. SO AN.

Hmm interesting. With my current build, the silicone cold side tube from my turbo compressor touches my lower radiator hose. Was wondering if getting this new part, throw a 16 an fitting with a 90 bend would solve my tight space constriction.

Yeah it would be going to a stock radiator.

Bump, any update on this?

Still planning on doing this, but not for a couple of months. Life got in the way. My company is shutting down my office, and I either have to transfer to another city or look for new employment.

edit:good reason, sorry, words in my head weren't making sense that day.
Also, xmas shopping is getting in the way, so 1-2mo's of postponement on my end.
How big is the interest list? I'm one.

Attached are renderings of the final designs I am getting pricing for. The main change is that I integrated the AN16 extension into the thermostat cover so that a separate piece is no longer required.

Hey Skou, this is totally up to you as you are the creator if this work, but it would be REALLY cool if you posted the 3D files for this for those of us with the tools to make this. Seems like it would be a fun couple parts to make anyway.

I just fitted a Begi coolant reroute spacer to a 2001 NB.My observations on their design may be of interst to you in your great project,
The BEGI design seems to be severely compromised by the need to clear the NA type coils. If you have an NB or a car without the rear coils this is bad. One of the consequences is the port for the temperature sensor is oriented way over to the hot side at about 10 o'clock. This requires you to lengthen the wires for the temp sensor.The conductors in this wiring are very fine and fragile.Making a good,durable connection is problematic. Repairing it after install would be very tedious. The BEGI design would be much improved if the coolant sensor port was oriented exactly like the original thermostat cover.That would mean no need to extend the wiring.This has been reported as an issue by others.
One other failing is the bolts BEGI supplied. Over-tightening steel bolts into an aluminum head is a needless risk. It would have been better engineering(IMHO) to supply over-length stainless steel, full thread bolts. Use a stainless nut+washer on each bolt. Run the nut up the full length of the thread to the head of the bolt. Gently torque the bolts in position using blue loctite. Then tighten the s/s nut on the s/s bolt to ensure a tight clamping force on the s/s washer+BEGI spacer + Kia water outlet. Use carefully applied, good quality self adhesive gaskets between both mating aluminum surfaces.
This is what I did because there are reports of the BEGI spacer leaking.If you then try to tighten the bolts they may damage the threads in the cylinder head.That would be a real pain to repair!
We still need a better solution to the EGR tube mod/lengthening required. The CSST solution is O.K. but the adapter fittings are too clumsy and long.
I hope this helps others who make this mod.

This will be nice!

Very interested in this. Looks like I may be able to use that fitting on top for turbo coolant feed as I ditched the stock oil cooler/throttle parts.

Interested in this, let me know when you have a price and ETA.

definitely want.

I'd take a set.

Tommy

In for pricing!

Since I would like to get this done on my end (not liking the stainless one I have built since I had to made a flange to connect to aluminum for the AN), you mind sharing solidworks files or even just the flange dimensions you have so I can enter it in solid works with some sort of a filler neck and have it cut!

Cheers.

https://www.miataturbo.net/attachmen...ine=1394824961
image ru

I finally got my life back on track and am resurrecting this project to see if there is still enough interest. To make it worthwhile, I would like to put together at least five "kits" which would include the following:

(1) Thermostat Spacer, Custom
(1) Thermostat Housing, Custom
(1) Water Pump Inlet Housing, Custom
(2) Water Outlet Gaskets, FEL-PRO 35251
(1) Water Pump Mounting Gasket, FEL-PRO 35457
(1) 5/16" Hose Barb to AN6 ORB Fitting, Anodized Aluminum
(1) 1/8" NPT Pipe Plug, Anodized Aluminum
(1) AN4 ORB Fitting, Anodized Aluminum
(2) AN10 ORB Fittings, Anodized Aluminum
(2) AN16 ORB Fittings, Anodized Aluminum
(2) M8 x 1.25 x 60 Socket Head Cap Screws, Steel, Class 12.9
(2) M8 x 1.25 x 65 Socket Head Cap Screws, Steel, Class 12.9
(4) M8 Washers, Zinc Plated Steel, Class 10.9

With a medium size USPS flat rate priority mail box and PayPal fees, I expect the total to be in the neighborhood of $350-375. I am confirming all of the costs this week.

PM me if you are interested. Thanks.

I'm interested too.
A friend of mine -in Trenton, NJ of all places- has a machine shop. He's specialized in prototype work and small production runs. Currently he's a bit low on work. I can ask him to quote you, if interested. PM me if you want.

Still interested but I can't send pm's, let me know when you get the details worked out.
TAD460@msn.com

Pricing came in for the thermostat spacer and water pump inlet. $90 and $103, respectively. A bit higher than expected, but the shop is local to me and does high quality work. Pricing for the gaskets, fittings and hardware is $75.60. So, minus the thermostat cover, the total with shipping and PayPal fees is $289.40. I expect to have pricing for the thermostat cover after the long weekend.

I have the following people tagged for the 5 sets.

1) skou
2) stefanst
3) Dahl460
4) ianboyd
5) UrbanSoot

Anyone else?

Awesome!

+1

Really glad this is coming to fruition.

Ooooh, tasty. PMing you.

I'll take a thermostat spacer and cover. I'll PM you!

I wish I could afford this right now.

I'd be on this like white on rice, but I got hit last week, and my MS3/Miata money is now going towards a new quarter panel and paint.

Good luck with the sale!

I very much appreciate your design work, and really love when people put cool products like this together on forums, but isn't the price of this not much different than buying any of the pre-existing coolant reroutes out there? I'm not trying to "hate", just thinking of ways to make it cheaper, because that's when it would be REALLY cool.

If his spacer which is being made in a quantity of five costs the same as Begi's significantly simpler spacer design which has sold hundreds, if not thousands, imagine how much Begi has been ripping everyone off for years on that niche product.

I'm not having these parts made for profit. All of my costs are a straight pass through. If I were to start selling them as a business, however, the prices would be significantly higher.

Since I had a similar design made and priced to be made, his prices are right on the money and he is not making profit, I can tell that much!