*HOW TO* Convert a nova expansion bottle to twin outlet

[AlanH]

Just on finishing my xe conversion and seen a lads gsi with an xe in, his expansion tank had another outlet tapped into it which i thought looked much tidier that a t-piece so thought i'd have a go, heres how i did it:
Firstly i had to find a piece of pipe the right diameter so that the hose would fit over (12mm OD) i used the dipstick housing from some horrible hyundai which i still have a length of if anyone struggles to find some. I drilled a hole in the top of the tank at the side (see pic for location, not that important as long as its above the water level) i then used a 12mm drill bit and reamed the hole out with the drill bit by hand. I did this as i find using a drill tends to ream the hole out a bit too large and ideally you need an interference fit for this to work well. I then cleaned the end of the pipe with emery paper, coated it in glue and tapped it in. once the glue had set i smeared some silicone round where it seals, job done! just need to cut the pipe down a bit.
If anyone is interested in buying one of these or wants their own done pm me.:thumb:

http://i265.photobucket.com/albums/ii227/alanhughes87/Photo037.jpg
http://i265.photobucket.com/albums/ii227/alanhughes87/Photo038.jpg
ps: maybe this could be made a sticky?

[Adam]

Have you tried it yet? Does it hold pressure???

[brainsnova]

not bad but your best to pressure test it to see if the glue etc will hold with the heat and pressure.

[Ernie]

much easyer just to fit a T piece in the hose imho.

[AlanH]

Yep holds pressure fine, tried to pull the pipe out quite hard and it never budged either, was a really tight fit in the hole

[cunit]

just don't bother with that other hose

[Rich]

its there for a reason lol

[mayhem]

i didnt use it, it something with the inlet iirc?

[dan16v]

Not knocking it, but id be very wary of that after the header tank has expanded and contracted a few times, as the glue and plastic will not expand/contract at the same rate!

[Ernie]

ive seen how much pressure i can cause to a Bailey header tank on a track session so think i could kill that in about a lap or two.

[AlanH]

gave this some serious abuse, got me to pvs and back, 3 runs up the strip and some serious a*** kicking including a good 10 seconds with the needle off the clock and buried into the reset button, still shows no signs of cracking or moving so think i may have proved you a bit wrong dan although i've never had the temp gauge above half, even in traffic so dont know how it would manage at higher temperature. wouldn't use it for a balls out track car either ernie

[Steve]

Not bad mate, I was thinking of doing something similar, or just fitting a cav header tank. At the moment ive just tapped it into the return which goes into the thermostat housing, which seems fine.

[dan16v]

Fair play then Alan, still would not use it on my car, but glad its working for you!

[AlanH]

only reason i did it that way is because it looks a bit better, i can plastic weld but I.M.O this is just as good, dont think it would work if the pipe wasn't as tight a fit as it is, really had to give it some welly to get it into place. will upgrade to a bailey item at some point as i'm awaiting delivery of a bottom end to convert to LET

[dan16v]

Cool, i have a bailey type tank, i had to get another take off welded on for the let, but i think bailey may do a let specific tank now with the extra take off.

[Adam]

Or just block the 8mil coolant outlet off, on the inlet, like ive done.
No need to have a pipe at all then :)

[Saloony]

Thats mine

http://i20.photobucket.com/albums/b204/Keiranova/100_0332.jpg

[dan16v]

that all needs to be coated matt black lol

[novaxe235]

it needs the correct size jubilee clips on it thats what it needs.

[trackdaynova]

as a few have said, I've never ran said pipe on any XE I've ever had, and they've all been track orientated/ abused :thumb:

[Ernie]

and it still is lol

[loggyboy]

its there for a reason lol
Being?

Mines been sealed with bolt and jubilee clip for the past 5 years and I cant think of a reason it needs to be fed back to the header.

[Jon_nova1]

This is a good idea in essence, but the silicone is a bad idea

you want to use epoxy resin! it has the flexibility and strength,

http://cgi.ebay.co.uk/WATER-CLEAR-CAST-Epoxy-resin-590g-kit-thin-sections_W0QQitemZ220438050814QQcmdZViewItemQQptZU K_CarsParts_Vehicles_BoatEquipment_Accessories_SM? hash=item335321b7fe&_trksid=p4634.c0.m14.l1262