Goce Posted October 10, 2017 Author Report Share Posted October 10, 2017 Today i continued with making the housing, first i drill it thru with 17mm drill as this is the size for the inlet port, then i drill with 32mm drill to depth of 41mm, then i used a brazed boring bar and staggered my cuts with 0,4 one for another to achieve the taper to mach the taper on the back of the fins on the water pump, next i made the nipple for the outlet pump next i need to weld it and drill the outlet port. This was precision work so i took my time to hit all my dimensions spot on and turn out really well, more to come. Quote Link to comment Share on other sites More sharing options...
Goce Posted October 11, 2017 Author Report Share Posted October 11, 2017 Today i continued with working on this housing, just as i weld the outlet nipple got a call about a guy selling an webasto unit with the pump i'm needing, so i went and bought the complete unit and when i tested the pump is not working, try taking it apart and find that is sealed induction motor with burn electrics and coils, second thought was i'll replace the motor only but as is an induction motor there is no seals i can't use it at all, back to the original pump build and i had a hell of a time drilling it at an angle, you can see my setup for holding my taper drill bit with an old drill press spindle and a hand drill, as last thing i painted it in primer to stop it rusting but the paint gun had some old paint and paint looks ugly but should protect it from rusting. Quote Link to comment Share on other sites More sharing options...
Goce Posted October 11, 2017 Author Report Share Posted October 11, 2017 Today i assemble the pump and tried to test it and the motor was struggling as soon as the pump primed the rpm dropped in half and the motor got over 100 degree celsius in less then 10 min, and the power counsopson went to 8 amps, so new plan is to make it belt driven and gear down to gain torque and lower the rpm, more to come. Quote Link to comment Share on other sites More sharing options...
Bean Posted October 11, 2017 Report Share Posted October 11, 2017 Any idea what the RPM of the fan motor is? If the pump is very efficient it wouldn't need much RPM so you could get away with a much higher ratio - say 4:1 or even higher if you have the room. Curious to see how it works! Rabin Quote Link to comment Share on other sites More sharing options...
Goce Posted October 11, 2017 Author Report Share Posted October 11, 2017 The clearances are very tight, so is very efficient spinning the pump by hand pumps water, i'll have difficult time chucking the pump in the lathe, so cut off the coupler and make v groove for the belt, fun times. Quote Link to comment Share on other sites More sharing options...
Goce Posted October 12, 2017 Author Report Share Posted October 12, 2017 Today i've spent some time reworking my previous coupling, first i chunk up the water pump in the lathe, i put the jaws on the flange that not sealing, and the 3 fins are contacting the jaws so i took it easy, made light cuts to make it round, then used a very sharp HSS tool to cut off the old coupling and make the belts groves, then i made a pulley for the motor and used couple of small screws to secure it as last i vent in the big garage and put couple of tack welds to hold them to a piece of pipe, and test it it now the motor doesn't getting that hot, and draws its normal 4,9 amps but is very loud, sound like a small kompressor, i've noticed the motor shaft has some runout and makes the whole assembely to vibrate, i'm very busy next couple of days but i'll try at list to get the heating unit install in the car and do some more testing before i install the pump it in my car, more to come. Quote Link to comment Share on other sites More sharing options...
Goce Posted October 13, 2017 Author Report Share Posted October 13, 2017 I'll have to go to work on the weekend so my plan to dedicate my time to finish this and couple other projects is not going to happen, but i still have an hour or two to spare at the end of each day, so today i started to install the heating unit, first looked around and try to place it in the engine bay where there is room, and only place i found is where this plastic box was sitting that use to house the engine ecu, so i removed it, its an mechanical diesel no ecu needed, and started to make the brackets, the first one i made is not visible but i used 40mm flat iron and band it and put couple of holes to bolt up, for the second i had an bracket for mercedes b class so i cut it in half and weld 25mm flat bar to attach in nearby ground bolt hole, then i used an 90 degree elbow for the exhaust from another unit to redirect the exhaust, which i still need to finish running to the bottom of the car and install a silencer, then i cut back the air filter assembly and fitted it to the unit so that part is finished, then i made a new bracket for the fuel pump and found perfectly located bolt hole in the radiator support and bolted it, lastly i removed the entire unit painted the brackets and put it back together in the car, i still have lots of things to connect and install to make this project finished. Quote Link to comment Share on other sites More sharing options...
Goce Posted November 2, 2017 Author Report Share Posted November 2, 2017 A lot has happened with this project last couple of weeks, i realized, i can't use the pump i've built, because of the power consumption it will drain my battery in no time, so after looking for some time, i bought two more webasto units and one had an working circulation pump, so i started with mounting that pump, and began the plumbing, i used many coolant hoses and aluminium pipes to make the connections for the coolant system, and used heat resistant insulation, then i plumed in the fuel filter via the bleeder screw, used a small banjo bolt and install inline diesel fuel filter, then i used stainless flex pipe and made the exhaust, and after i installed and tested it i realised that there just is not enough space, the unit itself produces a lot of heat and it will melt my headlight and core support,radiator, intercooler, so at the end i dismounted the unit all together and returned the engine bay to stock, i know if i keep it in the car i'll try to insolation it and end up burning down the car, next i'll like to look in to maybe installing a block heater if there is room . Quote Link to comment Share on other sites More sharing options...
tulaweb Posted November 14, 2017 Report Share Posted November 14, 2017 I've used a freeze plug block heater, in my 505 xd3t engines for years. Starts like summer in the coldest winter temps. It does take a couple of hours to warm up from really cold temps. On cold nights I use a timer to activate it a few hours before I need it. Quote Link to comment Share on other sites More sharing options...
Bean Posted November 14, 2017 Report Share Posted November 14, 2017 Any chance you have a part number? Or ideally the OD size of the freeze plug? Rabin Quote Link to comment Share on other sites More sharing options...
Goce Posted November 14, 2017 Author Report Share Posted November 14, 2017 I have a block heater from a mercedes, but is threaded for M38x1,5 treads, and it sticks out about 2 inches and this engine is so tightly pack with all the plastic intercooler pipes there's very little space, i'll need a flush mount one, i've called couple of parts suppliers that advertise importing parts for US vehicles, but i live so far south no one has ever heard about block heater, i'll keep looking, weather is getting colder. Quote Link to comment Share on other sites More sharing options...
Goce Posted January 20, 2019 Author Report Share Posted January 20, 2019 I wanted to update this thread, this winter we have had record low temperatures and snow, but the 605 has had no issues with fuel freezing, the factory fuel heater is connected and after a longer drive i've put my hand on the fuel tank and is little warm, it seems the warm return fuel is helping a lot. This year after changing jobs i'm using my car even more and last two months, i've been driving it in minus double digits with no difficulties at all, starts better then when warm. Quote Link to comment Share on other sites More sharing options...
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