custom external oil/air and oil/water build - Ford Powerstroke Diesel Forum
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  #1  
Old 09-08-2012, 03:47 PM
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custom external oil/air and oil/water build

Background: I have a 42 foot Toybox, which gets loaded with sand car and couple quads and bikes, the trailer weight alone sits right at 20k. Then I used to haul it all around NV and SoCal to major dunes. The truck ran too hot.

I got the BPD ext kit, and it did way better! But, i still overheat her (get oil into 250+ on long grades). I have the 08 front end so have extra room up front, built a custom setup to hold air/oil cooler out front, and that helped, but I need more. I talked to Ken at BPD and he is very knowledgeable and helpful. He mentioned a custom setup that he has done some personal testing on, and gave me some pointers. Thanks Ken. Anyway here it is in the making:


External Oil / Water cooler by MOCAL the largest one they make. Ran on many race vehicles and well tested in the race industry.


My Current setup as of this morning:



Parts laid out, im going to start with a parelle setup, the oil will feed to a "tee" and go through both coolers:



Pics of the cooler, oil comes in the channel, spreads out, around the fins, and exits:




This is picture of the Plug that goes in the inlet. If all of the coolant ran through at high pressure ,you remove the plug and water flows through middle. With my low pressure system (the old egr supply) I cap the inlet, water has to flow around outside channels, still fills the cooler at the back end, but is forced to flow around the outside.




Tomorrow I will re weld a cage to hold it all and try her out! Im hoping it will "warm" the oil faster when cold, and give me at least a 10 degree extra temp drop when hot. Ken and I figured it should. The oil will take the path of least resistance, which will be the water/oil cooler at startup as it will be warmer. Once hot, I will have to note what temp drops I see. Im very excited, did a lot of research and race vehicles using this exact cooler see major drops in EOT. I will keep this post up to date. Should have time to finish tomorrow. The oil is plumbed off the BPD ext kit, with Tees at the air cooler. The water runs from the exit at the oil cover (where EGR supply was) direct through the cooler and back to degas. I have the GOGO intake, with no egr components at all. I will let you know how it works! I timed my ECT and EOT rise from dead cold this morning. Once the install is done, I will try that again and post the difference in warm up time.

Last edited by jetjock15; 09-08-2012 at 04:55 PM.
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Old 09-08-2012, 09:47 PM
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Very interesting option.
My one concern would be with the coolant return to the degas bottle, that return port into the degas is very small on the I.D. (about 5/32"), I ran a 5mm drill into mine to open it up slightly. The coolant outlet on the BPD transfer block (and the outlet on the OEM oil cooler) is about 1/2" I.D. and uses 5/8" hose. You might consider splitting the return with a tee and returning into both of the vent/returns on the degas, or get a custom tee made that you could cut into the top radiator hose that would provide a 5/8" return port. Then you could use 10AN hose and fittings for the coolant supply and return.
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Old 09-08-2012, 10:31 PM
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This sounds pretty interesting. Tagging to see how it works out. If all works well I may try a similar setup minus the bpd cooler and try to ileviate the oil cooler problems with the OEM coolers.
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Old 09-09-2012, 06:45 AM
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good input artic fox. I have been running the GOGO stage 1 manifold for about a year now and have towed heavy over 6000 miles with it. It eliminates all egr and necks the coolant flow down to 3/8 line, back to bottle. Initially this seemed odd, but lots of guys runnin the GOGO setup without one failure of waterpump or related issues with the flow going right back to degas bottle in 3/8 line. For my bulletproof D cover, i switched out the water out fitting for one that matched when i first installed the GOGO and BPD cooler.
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Old 09-09-2012, 07:26 AM
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Are you running a different radiator/intercooler? Looked into a water/meth injection for those long grades?

Interested to see where this thread goes. Good luck.
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Old 09-09-2012, 07:56 AM
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I have heard that BPD was looking into using larger oil coolers for the DRW trucks, that might be a easier solution
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Old 09-09-2012, 08:12 AM
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Mike I have a banks intercooler, stock radiator. Water temps never been an issue, only oil. I have stayed away from injection kits just cause I'm not sold on reliability. But never did too much research.

Lubbock, I've been in touch with BPD tech plenty, this is the route that will offer the most EOT cooling.

Will work on it today and post more pics
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Old 09-09-2012, 02:30 PM
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Heres a pic of it together. Very frustrated, started it up and one end of the new cooler leaks. will have to order a new end gasket, very cheap, but i have to pull it all out agian, so a bit frustrating. seems like it should be a good setup when all done. Until next weekend then....

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Old 09-09-2012, 03:30 PM
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what is the pressure drop across the MOCAL ?
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Old 09-09-2012, 03:36 PM
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so oil flows in the rectangular areas on both ends and around the round cylinder.
And the coolant flows in the 20 or 30 little holes inside the round cylinder ?

Joe
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