GT-Forty.com

GT-Forty.com http://www.gt-forty.com/GT-Forty/Cooling_Sys.html This section will cover the Cooling System and components. In that the GT40 is a mid-engine car, there’s a lot of distance between the engine and the radiator. Also to consider is that the proximity of the front of the engine to the fire wall is exceptionally close - I’ve opted to use a remote electric water pump on this car. The 1-1/2” stainless steel coolant tubes run through the spine of the car from front to rear. I plan on wrapping these tubes with insulating wrap prior to their final installation. This section - like many others - is presented here as “IN-PROGRESS” - please check back periodically. Standard 289-302 Water pump It’s roughly 5-1/2” tall including the shaft. I’ll be installing a remote electric pump and will use this housing as a water manifold once finished. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#0 53c4e0bc-747c-435e-937a-95556784d156 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0631/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0631/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">Standard 289-302 Water pump<br/></p><p style="padding-bottom: 0pt; " class="Caption">It’s roughly 5-1/2” tall including the shaft. I’ll be installing a remote electric pump and will use this housing as a water manifold once finished.</p></div></div> I used a 3 jaw puller and removed the hub, then I knocked the bearing and impeller assembly out the backside with a dead-blow hammer. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#1 58e7c5ba-b2bb-411f-ac5c-f8567b5610a7 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0632/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0632/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_2">I used a 3 jaw puller and removed the hub, then I knocked the bearing and impeller assembly out the backside with a dead-blow hammer.</p></div></div> This is what the pump looks like after the bearing and shaft assembly is removed. (you’re not supposed to notice that I’ve already cut it) http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#2 f3d31b34-a6bc-48b2-83fa-018c1e2e0148 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0633/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0633/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">This is what the pump looks like after the bearing and shaft assembly is removed.<br/></p><p style="padding-bottom: 0pt; " class="Caption">(you’re not supposed to notice that I’ve already cut it)</p></div></div> I used a hacksaw and cut the top 2” off the pump. This now leaves the pump to be an even 2-5/8” tall. The bearing hole is 1-1/2” and will be blocked with an expanding plug. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#3 619dfafb-a32f-423c-96c8-31e425a12531 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0634/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0634/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_2">I used a hacksaw and cut the top 2” off the pump. This now leaves the pump to be an even 2-5/8” tall. The bearing hole is 1-1/2” and will be blocked with an expanding plug.</p></div></div> Here you see the perfectly round hole left by the bearing assembly as well as the weep hole from the bearing cavity. I’ll turn down a piece of alloy to weld or epoxy in place. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#4 cb5afb00-acc5-4d8e-8bd6-5a72454bf4fa http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0640/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0640/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">Here you see the perfectly round hole left by the bearing assembly as well as the weep hole from the bearing cavity.<br/></p><p style="padding-bottom: 0pt; " class="Caption">I’ll turn down a piece of alloy to weld or epoxy in place.</p></div></div> Backside view of the naked pump housing. I’ll bead-blast it and powdercoat it as well. This will now be known as the water manifold. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#5 b883c1c5-4e52-492a-acb8-a8d2627afa3b http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0641/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_0641/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="paragraph_style_3">Backside view of the naked pump housing.<br/></p><p class="paragraph_style_3">I’ll bead-blast it and powdercoat it as well.<br/></p><p style="padding-bottom: 0pt; " class="paragraph_style_3">This will now be known as the water manifold.</p></div></div> While I was in the process of cleaning up the housing, I decided to hit the chamber with my die grinder to allow it to flow a little more free. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#6 7007d9fe-36d7-45e7-987a-477e9c9aee71 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1142/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1142/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">While I was in the process of cleaning up the housing, I decided to hit the chamber with my die grinder to allow it to flow a little more free.</p></div></div> My friends down at RiverLake Hardware in Minneapolis let me use their 1-1/4” pipe tap to thread the housing for the AN-16 fitting. Freshly bead blasted & ready for powder coating. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#7 b9b43648-260a-43a4-af68-6320db397826 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1140/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1140/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">My friends down at RiverLake Hardware in Minneapolis let me use their 1-1/4” pipe tap to thread the housing for the AN-16 fitting. Freshly bead blasted & ready for powder coating.</p></div></div> After removing the heater hose port by applying heat and a bit of persuasion with a Vice Grip and a hammer - I tapped the hole with 1/2” NPT. This port will connect to my reservoir. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#8 05c0267f-304c-4650-828e-a9e7579d6e0a http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1141/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1141/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">After removing the heater hose port by applying heat and a bit of persuasion with a Vice Grip and a hammer - I tapped the hole with 1/2” NPT. This port will connect to my reservoir.</p></div></div> As you can see - I waited until it was powder coated before I decided to try and remove the other water port and tap. I ended up cutting it off - drilling 37/64” and tapping 3/8 NPT http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#9 de127a68-c615-4b2d-8269-e7271d305fc2 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1286/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1286/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_4">As you can see - I waited until it was powder coated before I decided to try and remove the other water port and tap. I ended up cutting it off - drilling 37/64” and tapping 3/8 NPT</p></div></div> The steel 1-1/4” NPT-AN16 fitting would only go in roughly 3/8” - I didn’t want to take a chance at splitting the casting by forcing it further. I epoxied in place with JB Weld. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#10 65c2a940-bd12-4d58-a8f3-3be3a86cce7d http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1285/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1285/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">The steel 1-1/4” NPT-AN16 fitting would only go in roughly 3/8” - I didn’t want to take a chance at splitting the casting by forcing it further. I epoxied in place with JB Weld.</p></div></div> Coolant manifold bolted up to mock-up block http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#11 20d555d4-db00-4c7c-8b32-355f60f87d9b http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1325/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1325/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">Coolant manifold bolted up to mock-up block</p></div></div> BMW 2002 80c Thermostat This will allow the coolant to recirculate through the system until it is up to temp when the bypass closes and routes the coolant through the radiator http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#12 713e60b9-81a1-4726-a57d-856690524cc1 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/33cd_1/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/33cd_1/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="paragraph_style_4">BMW 2002 80c Thermostat<br/></p><p style="padding-bottom: 0pt; " class="paragraph_style_4">This will allow the coolant to recirculate through the system until it is up to temp when the bypass closes and routes the coolant through the radiator</p></div></div> Coolant tubes - engine compartment side. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#13 a0ef2ee1-1739-4939-aab5-5281d86ef00e http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1265/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1265/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">Coolant tubes - engine compartment side.</p></div></div> Since I want to use AN16 lines in the engine compartment, I needed fittings to weld on. These came from Jegs and are mild steel since I was not able to locate stainless parts. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#14 1586856f-b139-492f-8994-8e2659ebab3c http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1263/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1263/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_4">Since I want to use AN16 lines in the engine compartment, I needed fittings to weld on. These came from Jegs and are mild steel since I was not able to locate stainless parts.</p></div></div> I machined the ends to fit inside the tubes and then cleaned up the transition to flow a little cleaner with less turbulence and restriction. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#15 295e128e-2fc3-4f1d-821d-47bb70ebe378 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1264/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1264/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">I machined the ends to fit inside the tubes and then cleaned up the transition to flow a little cleaner with less turbulence and restriction.</p></div></div> Steve at Carriage House did a great job TIG welding the fittings to the tubes. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#16 7b817170-a36c-411e-b602-6dad25674460 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1284/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1284/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_4">Steve at Carriage House did a great job TIG welding the fittings to the tubes.</p></div></div> 50 GPM Remote pump from Jegs. Also shown are their optional at additional charge 1-1/2” hose adapters. Outlet side shown http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#17 101f3ef2-1e8b-4fc1-8ea5-b7452d81c744 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1261/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1261/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">50 GPM Remote pump from Jegs. Also shown are their optional at additional charge 1-1/2” hose adapters.<br/></p><p style="padding-bottom: 0pt; " class="Caption">Outlet side shown</p></div></div> Here’s the Inlet side of the pump http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#18 72b1d0de-5f5d-4757-9224-9ef0d722c5d0 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1262/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1262/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_4">Here’s the Inlet side of the pump</p></div></div> Mockup of hose routing Don’t laugh at my use of tape and pipe insulation. :) BMW Stat housing is 1-1/4” hose size. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#19 92c7d0cd-8d7c-43b2-bbc9-599a4c3a6966 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1266/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1266/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">Mockup of hose routing<br/></p><p class="Caption">Don’t laugh at my use of tape and pipe insulation. :)<br/></p><p style="padding-bottom: 0pt; " class="Caption">BMW Stat housing is 1-1/4” hose size.</p></div></div> Just a side view. The hot line will be on the bottom of the tunnel to keep it further away from the AC lines and electrics that will also run through the tunnel http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#20 6392b88c-e00f-4205-a764-f0dd0b8f2cdb http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1270/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1270/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_4">Just a side view. The hot line will be on the bottom of the tunnel to keep it further away from the AC lines and electrics that will also run through the tunnel</p></div></div> It will be interesting to fab the “Y” manifold needed to accommodate the Bypass hose http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#21 0fdcead7-c3e3-486b-ae57-1b82273885d5 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1268/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1268/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">It will be interesting to fab the “Y” manifold needed to accommodate the Bypass hose</p></div></div> Water pump mounting bracket was made from 1/8” 6061 Aluminum http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#22 fca7a93a-e9e1-441d-9463-e946c1b76a82 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1299/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1299/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_4">Water pump mounting bracket was made from 1/8” 6061 Aluminum</p></div></div> Pump held in place by 4 - 3/8” stainless socket head bolts. The bracket will be bolted solidly to the floor of the front tray. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#23 8c9cad7f-6472-498a-be55-edb079d13569 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1300/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1300/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">Pump held in place by 4 - 3/8” stainless socket head bolts.<br/></p><p style="padding-bottom: 0pt; " class="Caption">The bracket will be bolted solidly to the floor of the front tray.</p></div></div> Custom aluminum water manifolds were created by Mike Kuhn at Kuhn Auto Specialties (find a link to his shop on the LINKS page) http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#24 0cb242e7-edcc-458b-8d0d-51292a8d3d14 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1740/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1740/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_5">Custom aluminum water manifolds were created by Mike Kuhn at Kuhn Auto Specialties (find a link to his shop on the LINKS page)</p></div></div> Merge Manifold - this is where the bypassed coolant comes in on the angled tube and is routed back to the water pump. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#25 299ad839-dd84-43da-87bd-3a40b5d361e7 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1741/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1741/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">Merge Manifold - this is where the bypassed coolant comes in on the angled tube and is routed back to the water pump.</p></div></div> I decided to use a BMW external bypass thermostat. It had 1.25” fittings and one was at an angle. No problem. Mike straightened things out with these custom swedged tubes. http://www.gt-forty.com/GT-Forty/Cooling_Sys.html#26 7af246bc-8d0f-4a78-bb30-24cdc5866b06 http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1742/thumb.jpg http://www.gt-forty.com/GT-Forty/Cooling_Sys_files/Media/IMG_1742/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_5">I decided to use a BMW external bypass thermostat. It had 1.25” fittings and one was at an angle. No problem. Mike straightened things out with these custom swedged tubes.</p></div></div>