Aluminum oil fill/filter cap/DIY secondary oil cooler - Ford Powerstroke Diesel Forum
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Old 03-08-2013, 09:02 PM
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Aluminum oil fill/filter cap/DIY secondary oil cooler

So I was thinking about getting some aluminum oil bypass filter caps for the OEM oil filter and filler cap, the kind with 1/8th in NPT threaded holes in the top, some PTFE (aka, teflon) braided steel hose assemblies with -8 or -10 AN fittings, some AN to NPT adapters, and then use a aluminum fluidyne fluid cooler and set up a DIY air/oil secondary engine oil cooler. Suppose I would have to fab up a mounting bracket, but it shouldn't be that bad....I plan on mounting it on the passenger side of the radiator, kind of where the BPD 6.4 oil cooler half kit would go....I also may plumb in a bypass filter kit while I am at it, filter bases are fairly cheap and they come in a lot of thread sizes to fit almost any filter out there....Although I might just add the extra filter in later, I don't plan on running extended OCIs anytime soon.

Basically my idea is to have a swivel adapter mounted in the oil filter cap, in which would feed the oil cooler with high pressure oil through the braided PTFE lines, then would return to the engine through the line to the aluminum oil filler cap (will have a CCV mod in place to avoid a very bad deal of oil being sucked into the CCV tubing, then the intake...not good) There would also be a bypass thermostat installed to allow the engine oil to return to directly to the engine fill bypassing the air to oil cooler if the oil is not hot enough to need cooling....

I already have the lines, a fluidyne cooler, bypass thermostat, all left over from another project...So I am getting close to installing this in my truck....need some adapters from aeroquip yet and maybe the bypass filter/base and the all important aluminum caps...


1) Who makes the best aluminum oil filter and oil filler caps with NPT swivel fittings installed? I see NUC motorsports, my first choice, is out of stock...

2) Anyone else ever try doing this DIY style? Ive done many projects like this and I am competent in my abilities, But if someone has tips to help me avoid a mistake I am all for it...

I'm basically making a bypass filter kit and using bigger stronger lines and a cooler instead of a bypass filter....I just want to ensure my oil cooler lasts a long time and ensure proper cooling/deltas while towing very loads....mine are getting goofy at times with my big 5th wheel, nothing crazy, but they are right at the exact specs of "normal"...Also I can do this for a far lower price than the BPD kit, I may remove the oil filter cannister all together for a cleaner install, move the oil filter and change it to a spin-on and bassically make my own version of the oil cooler half kit....

Any advice is greatly appreciated guys!!


Last edited by rt_hawk; 03-08-2013 at 09:11 PM.
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