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

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/i...7/Photo037.jpg
http://i265.photobucket.com/albums/i...7/Photo038.jpg
ps: maybe this could be made a sticky?

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

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

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

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

just don't bother with that other hose

its there for a reason lol

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

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!

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.

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

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.

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

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

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.

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

Thats mine

http://i20.photobucket.com/albums/b2...a/100_0332.jpg

that all needs to be coated matt black lol

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

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:

and it still is lol

Quote:

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Originally Posted by Rich

its there for a reason lol

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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.

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-CA...4.c0.m14.l1262