More Plastic Cooling System Component Solutions?

[8SidePolygon]

I am aware of the aluminum thermostat housing for the Gen I (I have installed one myself). I'm curious if there are other plastic components that can be replaced by metal ones without going to a machine shop. I'm sure making an aluminum degas bottle would be doable and not too difficult given the proper skills, and rigging up an aftermarket radiator would also be doable as well. But I'm talking about like a water crossover or an upper radiator hose (the plastic on mine broke off completely on the inside of the hose almost completely disconnecting the hose going down to the dccv was worried she wouldn't make it to my garage). Was just wondering if there were options out there, not too optimistic though considering the lack of aftermarket support on these cars.

 

[AmsterDutch]

I believe Ebay has an aluminum degas bottle only bad thing is its all one solid piece

 

[AmsterDutch]

I used to have 2 LSes and a LSE but sold them now I'm driving a MKX

 

[8SidePolygon]

I believe Ebay has an aluminum degas bottle only bad thing is its all one solid piece

Yeah I've seen them, but tbh I'd rather just learn how to weld and make one myself. I'm more so looking for alternatives for the water crossover and upper radiator hose.

 

[clubairth]

It sure is needed so post back if you do anything.
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[04_Sport_LS]

Yeah I've seen them, but tbh I'd rather just learn how to weld and make one myself. I'm more so looking for alternatives for the water crossover and upper radiator hose.

Tig welding aluminum poses many problems to beginning welders. Sign up at a local community college and take a night course.

 

[04_Sport_LS]

There is a guy on this forum that makes aluminum cooling system parts for the LS, but they aren't cheap because he machines them.

 

[8SidePolygon]

Tig welding aluminum poses many problems to beginning welders. Sign up at a local community college and take a night course.

Yeah I've heard that aluminum is typically a lot harder to weld with than steel/iron. I'll definitely look into that though, thanks for the advice.

 

[04_Sport_LS]

Tig welding also requires special equipment.

 

[SteveOwens]

There is a guy on this forum that makes aluminum cooling system parts for the LS, but they aren't cheap because he machines them.

Yes, i have a machinist make three sets on the engine cooling tubes rad to thermostat return and two degas tanks. They are the answer to highway maintenance issues. Currently the thermostat housing iz being made. He also added a reverse cone filled with the same elastomer as the trans mount on the motor mounts that ressemble an AM unit to stiffen the rubber mount, found that one out by accident. The transmission mount plate was machined with a much stiffer carbon fiber infused elastomer molded mount helps insure firm acceleration. The rear roll bar mounts were converted to steel. I haven't had the time to surgically put those in even though a one inch access hole was sawed above the fourteen mm headed bolts. What the real power adder to the wheels is to enlarge the tranny cooler lines to ( DNRCUSTOMS 3/4-16 ORING BOSS ) 5/8" dia thru two F67Z-7A095-BA (11/16-20 )coolers mounted under & back on the internal bumper. These are some of the things i have done with some amount of failure. If you want to contact this machinist let me know.

 

[Liquidlounge]

Steve - So you are having a Gen 2 (2003 & up) aluminum thermostat housing made? If so, I would like to see what it takes to get on board with this.

 

[Liquidlounge]

I have an 03 Thunderbird btw and I would think that there would be an interest amongst T-bird owners also.

 

[SteveOwens]

Liquid, the thermostat housing was the last of the plastic to 6061 conversion. I do believe that part is in the long list the machinist is working on. He has the Motorcraft thermostat parts bag to ensure proper fitment. The DCCV for the heater core control hasn'tever leaked but moght ask him the make it also. I had three full sets of the engine coolant piping with one set installed on an 06 LS. I don't do a price per part basis with him so ill ask for one more thermostat housing for you. Parts from him come as machined, but i get the batch anodized black for corrosion prevention. I did have a custom radiator made with an oem example sent to Ron Davis Racing Radiators and had it also anodized black. Great work! It still with him if you want one made.

 

[Liquidlounge]

Steve - I PM'd you my number. These items you have done seem like a great idea and address the biggest (fatal) flaw in an otherwise pretty sweet motor.