Another oil cooler project By Bashan (Read 2,758 times)

[Bashan]

I think I missed the wave of enthusiasm for oil coolers which kind of surprises me since summer is officially here. But this project is fueled by the need to get Frankie, my naked scooter, up to speed for a summer's road trip. We're either going to trailer a couple scooters up to Mamoth Cave in Kentucky to meet my flakey sister-in-law (hi Lene), or (my druther) go ride the Serpent's Tail. Frankie does OK with the heat but I'd like a little added security if we're going to flog him on the Tail.

My thanks to Cruiser for turning me on to Sliconeintakes.com where I got the radiator and fan. Also to 13lky2 (you doing OK Bud?) for bouncing some ideas back and forth on PMs.

I haven't did anything yet other than ogle all the cool stuff I got in the mail. Here's a picture of what I'm going to work with:

Front L to R: oil cooler & fan, Carter fuel/oil pump, Top: oil temp gauges

Here's a closer look at the radiator and fan. The radiator came with 1/2 NPT fittings and I'm still trying to find a reducer to a 3/8" barb to match the pump fittings. The fan feels industrial but is only supposed to draw 2 amps:

The Carter pump was a bit of a disappointment in that it says to use a 10 amp fuse. That's more draw than I wanted but I think I can work around it:

The oil temp gauges have an electric sending unit and were on sale from Harbor freight for $12.00! I figure I'll put one at the beginning of the system, one at the end, and then hopefully I'll be able to see if the system is working. They draw less than an amp.

I had originally planned to mount the radiator on the front to simulate the look of an old '30's auto:

But it had also crossed my mind to set it on the back rack running horizontal and mount the fan on top. It fits like a damn glove on the rack actually making a clicking noise as it settled into place. I think that's where it wants to be. Hey, I got voices in my head, there's no reason inanimate objects can't talk to me too .

Here it is with the fan sitting on top:

I'm pretty sure I'm going to draw from the left side drain plug and have the return either be the oil screen plug, or the valve cover! I'd like to get some thoughts on that concept. I was thinking I could put an o-ring compression fitting through the valve cover and have it drain cooled oil down through the timing chain shaft. That would give it an even greater opportunity to cool before it got to the crankcase.

Well any thoughts on this project would be welcome as I'm not entirely sure how I'm going to proceed. Then, this winter I plan on taking Frankie's engine apart and reassembling for a library tech post. Maybe an FI kit too?

[sprocket]

Nice parts Bashan!!! If you can get that happening that is great...

[13lky2]

I'm still here bud! Those are some nice looking parts you rounded up, I might have to swing out there and check out the finished product.

(Off Topic) Still in pretty decent pain, but managing it with meds. Insurance is working on the claim and they came by today to asses the damage to the scoot. Ready for the break to heal so I can ride again... the cage puts me to sleep.

[Bashan]

I've had to put the oil cooler project on hold since Sue and I have decided to go ride the Dragon't Tail in North Carolina. However, I have decided to move the cooler down on the floorboards. There's a couple reasons for this, one is that folks wanting to do this can make a few mods to their footrests and still have ample room for storage.

The other is that with the cooler this low the whole system will be within the sump of the engine. I won't have to worry about check valves and air getting into the system:

Here it is with the fan sitting on top, I might have to mount it underneath to make room for the footrests:

Anyway, we're leaving Saturday for the Dragon and I'm going to spend Thursday getting ready, so the oil cooler project is going to come to a screaching halt for a bit. Rich

[Bashan]

Well we're back from riding the Dragon's Tail and had a helluva time. I'll get a post together over on the pics and vids board when all the pictures are in. I did a little more work on the cooler and think I'm zeroing in on the final product. The first thing I had to do was get a NPT fitting on the left side of the scooter where the oil will draw from. I didn't want to tap and leave some metal fragments in the case so I JB Welded a fitting through the left oil drain hole. After 24 hours it's like a piece of the case:

Here's a more macro view:

I've already got my supply nipple JB Welded into a screen drain plug:

Now I had to figure out how to do the brass fittings. Originally, I wanted a drain valve off of the back and a temp sensor:

But first I had to get a "T" on with some thread sealer:

So with the temp sensor and ball valve on I ended up with this ridiculous array:

So on to plan B:

With this set up the oil will pass over the temp sensor giving a more accurate reading; here's a view from the front:

So hook up the hose:

And run it up to the oil cooler:

Of course you've got to leave enough play in the hose for the engine to move forward and back:

Now comes the tricky part hooking up the right side with the 10 amp pump. I've been brainstorming with Sprocket trying to figure out a way to energize this puppy. Rich.

[Bashan]

Well I said I'd finish this up so here goes, the hot oil comes out of the engine case on the left side using an 12mm to 1/8 NPT adapter:

Then the 3/8" black fuel line runs up to the oil cooler with a drain plug (red), cut off valve for filling (yellow), and the first temp sensor (green).

Next the line enters the oil cooler on the left side:

I was assured by the guy at the hardware store that this fuel line would easily stand temperatures up to 200 F and he was right. Then the oil makes it's way across the cooler and exits through this line around to the intake on the pump:

The green arrow shows the filler spout for the whole system, and the yellow and red are a shut off valve and the cool side temp sensor:

The oil tracks along the right rail, does a U-turn, and goes back under the center of the bike:

The system terminates in the oil drain plug. I know some guys have drawn the hot oil from this side but I felt it might take oil away from the internal oil pump which draws from this point:

Here's a macro view with the system in place but not wired in:

Here's a close up of the busbar I made to hook all the AC wiring to:

Here's a close up of the oil pump:

This is the ATC fuse board for the bike on the left side of the steering head:

Here's the cobbled together dash with the temp gauge and voltmeter:

Here's the $10.00 worklight from Wally world running off of the stator AC:

And here's a couple Youtubes that take you on a tour of the scooter and show you how the oil cooler works. Rich

[sprocket]

Very cool Rich, very cool... now the question is HOW cool......?

Only thing ...I would use a 90 degree elbow on the bottom oil drain plug...

[Bashan]

Sept 20, 2011 18:19:00 GMT -6 sprocket said:

I would use a 90 degree elbow on the bottom oil drain plug.

[/b][/quote]
I Know! What was I thinking? I made this thing with JB Weld and then went DUH, could have used a ninety:

I'm ordering a Trail Tech R/R and will rewire a GY6 stator for the charging system. I'll make a new drain tap and try to organize the dash a little more before retiring this for the winter. Rich