there are all sorts of holes with allen plugs in the exhaust side of the head. that is behind the tsat.

 

I was thinking about making a false space between the block and the t-stat. In other words, making a spacer the same configuration of the t-stat housing and bolt pattern and having a threaded female port on the side for a sender and/or eventually a pressure relief valve. Just something I was thinking about...

 

TRIK,

I like it!! Great idea!!!

Do you think it would be better to put it toward the back??? It seems wierd that we are only hearing about the rear plugs blowing out.............

 

that's a pretty good idea....now the question is what PSI are they blowing the plugs at?????

 

Well, I've heard that guys who have blocked the rear plug have been losing other plugs along the side of the block. Once you put a bandaid on the weakest link, it seems the next weakest link will step up to the plate. I think the reason the rear plug blows first and most of the time is because number 6 cylinder tends to run the hottest. So you've got us guys running ALOT of extra fuel thru the cylinders creating extra heat, number 6 is the hottest, the rear of the block expands ever so slightly, extra pressure in the coolant passages from high rpm's and bang, out comes the plug.

As to how much pressure is created, I'm going to fab up a pressure guage in the cooling system somewhere and watch pressures for awhile. I've just got to get the time to do it...

 

I've heard them talk about this a lot over at TDR and it seems that 50 psi came up several times.

 

We will have to see about that???????????????????????????????


You would think that there are going to be many other problems before you would see over 50 PSI in the cooling system.

NO other system out there runs over about 16 PSI, cap pressure that is.

 

It can easily get there with high RPM and a closed or partially closed thermostat. The 15 or 16 psi caps only control the water pump suction pressure. The downstream pressure can easily reach 50 psi and above, in the block between the pump outlet and the thermostat.

Even a 100% open thermostat has a delta pressure where the block pressure will be higher then the radiator cap pressure.

 

For whatever it's worth, I seem to remember seeing a spec on an older Cummins, (I think it was a 1982 K-Series) for the internal water pressure and it was 65psi. That was only a 2100 rpm engine.

 

[IMG][/IMG]
there is my roughed out plate. i need to check it for fit, then smooth it out and template it for you guys. yes it is upside down. sorry.

 

ZILLA04




Looks like a nice piece!!!!!!!!!!!!!!!!!!!!!!!!!!! Can't wait to here how it works out and installs!!!!

 

thanks, you're easy to impress. it feels like a hack job to me, but once i ensure the fit, i'll fix the finish.

 

I think a pressure releif of some sort is the best idea yet, the 06 we have been fighting is at the dealership now and i doubt they will fix it. We blocked off the rear and are now losing the one behind the turbo. Loctite JB weld, nothing will hold it in there I was thinking about tapping a AN fitting and hose to that plug that returns to the radiator.

 

got the plug and plate installed today. took 10 minutes. layed over the valve cover to install the passenger side bolt. reached in through the drivers wheel well to install those 2. just alternately tightened them until the plate was flush with the block.
then did the tstat mod. clipped 1 barbell. time was less than 5 minutes.
drained the little coolant that was left. refilled with extended life, distilled water, and one 15 oz bottle of diesel water wetter. and went for a gentle drive to purge air and check for leaks.
with the tstat vented, it does take longer to get to temp, but it does reach the same spot on the gauge it did before. i am happy, and back on the road.
i made a template of the plate. you guys want me to mail you a photocopy, then shoot me a pm with a mailing address.

 

so does ypur plate rest/seat against the freeze plug it's self???
the ones on TDR have the aluminum plug piece hooked to the block off plate and that holds the plug in place????