#4 coolant mod

[shelbyES]

If I can do with engine in car, is there a way to not get crap in the head and water pump?

[butchsuppe]

Use a vaccum cleaner next to the drill + tap, or use alot of grease on the drill +tap to glue the chips to it. After tapping you could run a garden hose to the rad to flush out the hole you just tapped.

[rbryant]

Use a vaccum cleaner next to the drill + tap, or use alot of grease on the drill +tap to glue the chips to it. After tapping you could run a garden hose to the rad to flush out the hole you just tapped.

Yea take off the thermostat and disconnect the all of the radiator and heater core lines then run the water into the waterpump inlet hose and it should flush the shavings out either the newly tapped holes or the waterbox.

Realize there is still some chance of not getting everything...

I would recommend either the VW 1.7 outlet or simply putting a 3/8NPT hole on the side of the head and running it from there to the heatercore. Of course you can also run a cold line from the pressure side of the waterpump if you prefer that method.

-Rich

[shelbyES]

Cool! thanks guys!

[black86glhs]

HEHEHEHE....Rich said, "tapped hoes!!!!"

[butchsuppe]

^^^^ Good eye, I'd like to tap some hoes.

[rbryant]

^^^^ Good eye, I'd like to tap some hoes.

Where I don't see such a thing in the post...

Ok so I typed a little too fast and just fixed it.

-Rich

[black86glhs]

Where I don't see such a thing in the post...

Ok so I typed a little too fast and just fixed it.

-Rich

LOL!!!

[tmef]

I tried something a little different. I filled the freeze plug with JB weld then drilled and tapped the hole for the fitting through that. Then I glued the fitting in place with JB weld also. I T'd the line into the bypass line right before the radiator. Cheap, easy and seems to be holding up so far. Time will tell.

[rbryant]

It looks nice and it should work as long as the hose doesn't pull the plug out. Nice to see that you teed into the waterbox line properly!

-Rich

[rbryant]

I took a few minutes to mess with my head that is forsale because the JB welded fitting might have been scaring people off and I figured I might as well implement my idea and document it.

I hit the 1" brass fitting that was JB welded in with a 1/2" impact gun and it barely came out. I then figured out where to put the VW housing on the head and drilled and tapped two M6x1.0 bolt holes to hold it on. It looks like it belongs there. I went slightly too far with one and hit the water jacket (but that is no big deal as lots of bolts in the head do that). The other bolt is fully blind so it won't be a problem. If I did it again I would have put a drill stop on it and not gone quite as far.

I will add pictures tonight.

-Rich

[black86glhs]

I took a few minutes to mess with my head that is forsale because the JB welded fitting might have been scaring people off and I figured I might as well implement my idea and document it.

I hit the 1" brass fitting that was JB welded in with a 1/2" impact gun and it barely came out. I then figured out where to put the VW housing on the head and drilled and tapped two M6x1.0 bolt holes to hold it on. It looks like it belongs there. I went slightly too far with one and hit the water jacket (but that is no big deal as lots of bolts in the head do that). The other bolt is fully blind so it won't be a problem. If I did it again I would have put a drill stop on it and not gone quite as far.

I will add pictures tonight.

-Rich

Rich, which VW model and year is the housing you are using? I'm thinking of getting one as a backup.

[Captain Chaos]

Try applying pressure to the radiator hose so it squirts coolant out as soon as the bit breaks through the housing.

[rbryant]

Rich, which VW model and year is the housing you are using? I'm thinking of getting one as a backup.

Early to Mid 80s rabbit/golf with a SOHC gas engine. Some of them are plastic some are aluminum. Both would probably work just fine. The aluminum one is better overall and you can also drill and tap the boss on the housing for a 1/8NPT temp sender if desired.

The numbers on the housing don't seem to work at the VW dealer but I am sure if you go you can figure out what year has the aluminum housing.

-Rich

[rbryant]

here are the pics.

The housing is 1" so it would need a 1"->5/8 line but they are available if browse the shelf at the parts store.... Or you could use the VW line I bet.

[black86glhs]

here are the pics.

The housing is 1" so it would need a 1"->5/8 line but they are available if browse the shelf at the parts store.... Or you could use the VW line I bet.

Rich, thanks for the info on the housing. That looks pretty good on there. Finding a reducing hose coupler isn't too hard.

[rbryant]

Rich, thanks for the info on the housing. That looks pretty good on there. Finding a reducing hose coupler isn't too hard.

I think there should be a 1" to 5/8" reducer in all rubber for some application out there. I will have to look the next time I am at autozone. I usually just ask to go behind the counter and look at what they have and they are cool with it.

I got a 3/4->5/8 hose for my SRT4 swap that way and there is also a nice one for the commonblock waterpump outlet that I have found that way.

-Rich

[mcsvt]

Rich looks good. Do you have a picture with the housing off?

[rbryant]

Rich looks good. Do you have a picture with the housing off?

Not handy but I can take some in the next few days.

I just sanded the surface to be sure it was flat and didn't have any debris left from the JB weld issue.

The housing is an oring about 1/8" larger than the hole.

-Rich

[boboli]

here are the pics.

The housing is 1" so it would need a 1"->5/8 line but they are available if browse the shelf at the parts store.... Or you could use the VW line I bet.

I just wanted to post for anyone looking for a hose, i found one from a 75 vw rabbit gas motor. It has a 15/16 into a 90 degree bend into 5/8 size hose, total length is 12 inches
gates part # is 21458 and I got it from checker for $13 and it came in the next day.

I also found an aluminum water neck for the end of the head off of a 77 vw rabbit gas motor @ the jy, and it has 2 sensors already in it ( 1 in water, the other is not) and it has a 1/2 coolant line coming off it ( if the large water neck points to the ds fender this would point to the firewall or the radiator, depending on how the water neck is mounted). I was thinking of making this the turbo coolant return, but i may just go oil only for the turbo so I may have to plug this. Just thought I would list another option.