A few updates & pictures...
Haven't gotten much done last month, just enjoying the last of the summer.
Re-assembled the bottom end a few days ago; while it was apart I took the opportunity to get ARP studs for the mains caps. All together and rotating freely! Replaced the one oil ring that broke the first time.
Oil Cooler System:
Here's what I'm putting together... B&M 19-row cooler up front in the top opening, I carved out a section of the vent scoop to provide some room for it. I'm keeping the stock oil warmer, but eliminating the filter with a spin-on adapter, the lines then go to a remote dual filter station, I'm going to have a regular filter on one, and the Amsoil 2-micron super filter on the other. Oil then goes to a thermostat, where it's routed either to the cooler, or back to the engine if below 175 deg. Planning on 1/2" line, not sure yet if I'm using AN fittings or just barbed push-on fittings.
Intercooler:
This intercooler
and this radiator
The radiator will be mounted up front, in the lower opening, as shown mocked up here;
Almost a perfect fit, could have gone even longer if I'd wanted by opening the sheetmetal on the passenger side more... there's a big void space behind there.
I've already removed the support bars, flush with the bottom of the opening; I'll cap the rod ends, and they will act as supports for the radiator. The mount tabs will attach through the sheetmetal on the bottom lip, and through an inner lip on the top. The rod removal was necessary due to the space they take up, even though the rad is only 2" thick, the rods make installation very difficult... and by tieing the radiator frame into the sheetmetal top and bottom, I figured it would make up most of the structual strength lost (if any). It will have to be offset to the left a few inches to provide room where the stock radiator thermo switch sticks out.
Pump is the Bosch unit used on many different cars (TDIs included)
Now to the engineering project of the week; the IC water resevoir
I wanted to have at least a 5-gallon resevoir somewhere in the intercooler system, but was having problems working out where to place a rather large tank. It hit me that I have a large unused space where the spare tire used to live, before I went 15" and big tires. However, that space is shaped... well, like a spare tire, and I could not find any tanks that would fit comfortably and without a lot of modification to the van itself. SO... we had a 55-gal plastic chem drum laying around (as one does) and I thought that might work, so I broke out the Sawzall and got to cutting... I cut off the top lid, leaving a 2" flange, then started with about 10" of the bottom, and cut it down until the flange fit snugly inside the bottom tray. What I was left with is a spare-shaped tank that holds 7 gallons. I have two 3/4" plastic boat fittings for in & out duties.
Then I found some hose... and I mean HOSE... on Ebay... 25 feet of this stuff for $0.01. One penny (plus $20 shipping
) for some seriously overkill 3/4" hydraulic hose. This stuff will outlast the van. I was expecting glorified garden hose!
Think this will hold up to intercooler duty? Yes, that's steel mesh reinforcing, two layers of it.
Stock Vanagon radiator fan, in case you've never seen one (A/C equipped van originally) This thing could power a small hovercraft.
Cat provided for scale
Finally, the intake... PD150 right-hooker and TDI Parts intake tube. The DieselGeek part (on the left) is too small!