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Thread: Rebuilding Thermostat Housings and Replacement Flanges

  1. #16
    Join Date
    Feb 2016
    Posts
    54
    Quote Originally Posted by jb351 View Post
    Made up a batch of flanges this week. Thanks to some great people on here I have some cores on the way too so I will be able to do an exchange/refundable core charge thing to speed things up a bit very soon.



    I also started development on an adapter that will work with the cheap aftermarket thermostat housings that currently don't work with SC's. It would be nice to have another option than just the old housings. I should have a CAD model done by the end of the weekend.
    My thermostat housing has some pit damage but the flange looks ok, so rebuilding mine would be a waste. That will be cool to see how those aftermarket ones look after you make them work for the SC. Keep up the good work!

  2. #17
    Join Date
    Oct 2003
    Location
    Allentown, PA
    Posts
    971
    My housing came in and it looks in good shape. Please PM me the address. I assume the housing rebuild includes a new flange?
    J.Miller
    1990 XR7 and 1955 F250!

  3. #18
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    Quote Originally Posted by J dot Miller View Post
    My housing came in and it looks in good shape. Please PM me the address. I assume the housing rebuild includes a new flange?
    Yes. New flange welded on, new gasket and refinished.

  4. #19
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    I was able to spend a few minutes this past weekend finishing the CAD model for a prototype adapter that will work with the generic aftermarket thermostat housings and then cut it out on the mill yesterday. I still have some development and machine work to do for the the fittings and bleeder but the housing itself is essentially done. That stuff will wait until the next time I order fittings/metal. It is essentially a 6061 aluminum sandwich with a gasket on both sides that would go between the intake manifold and the generic housing. It is currently a bit thicker than it probably needs to be at 1" thick but I can probably cut it down to around 0.700-0.750" or maybe even a bit less. The sealing surfaces were not machined yet as I am still working on them. A curious thing about the generic 3.8 SC housing that I bought from Rock Auto is that the flange on it is the same as the SC flange but mounted upside down on it. It is almost as if the engineer that copied it accidentally mirrored it in CAD before they had the tooling made for it and they got stuck with having to use them.




  5. #20
    Join Date
    Apr 2003
    Location
    Ventura, CA
    Posts
    1,917
    Wondering if you have any complete thermostat housings ready to ship out?

    I thought I had a spare I could send as a core, but I can't find it.
    Be excellent to each other.

  6. #21
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    Quote Originally Posted by Mercutio View Post
    Wondering if you have any complete thermostat housings ready to ship out?

    I thought I had a spare I could send as a core, but I can't find it.
    I have a couple of spare cores. I can make one up this week if you want.

  7. #22
    Join Date
    Apr 2003
    Location
    Ventura, CA
    Posts
    1,917
    If you can, that would be great. Please PM me the payment info and I'll send it to you.
    Be excellent to each other.

  8. #23
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    Quote Originally Posted by Mercutio View Post
    If you can, that would be great. Please PM me the payment info and I'll send it to you.
    PM has been sent.

  9. #24
    Join Date
    Apr 2008
    Location
    Maricopa, AZ
    Posts
    41
    I'm looking for one too. Can please let me know if you have another one.

  10. #25
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    Quote Originally Posted by SC1day View Post
    I'm looking for one too. Can please let me know if you have another one.
    Hi, I just sent you a PM about it.

  11. #26
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    After a long break I jumped back on to the adapter to make common new replacement housing work with an SC intake recently. I made a few prototypes up trying a couple of different things and on the same morning when I was finishing the design on the next prototype which was to go out to be tested very shortly I ended up getting laid off for a few weeks at least due to the virus screwing with my workplace so that will have to wait for a bit unfortunately. Here is what the latest version would have looked like.


  12. #27
    Join Date
    Apr 2003
    Location
    Ventura, CA
    Posts
    1,917
    It looks as if you could use a more conventional thermostat gasket with your design. My 4.2 F150 uses an O-ring gasket that I like a lot more than the paper SC thermostat gasket. I'd be all for using that design on my SC.
    Be excellent to each other.

  13. #28
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    Quote Originally Posted by Mercutio View Post
    It looks as if you could use a more conventional thermostat gasket with your design. My 4.2 F150 uses an O-ring gasket that I like a lot more than the paper SC thermostat gasket. I'd be all for using that design on my SC.
    Thanks for the feedback. Good suggestion, thanks. I had been considering an o-ring but had not though about adding it to this revision but giving the fact that I now have an excess of time I will see about adding it. I would rather an O-ring over a gasket any day.

  14. #29
    Join Date
    May 2018
    Location
    Ontario
    Posts
    4

    Housing rebuild

    Hello, are you still rebuilding the stock housings? I can send a core if so, how can I get the address etc. Thank You. Glen

  15. #30
    Join Date
    Oct 2018
    Location
    Nova Scotia, Canada
    Posts
    142
    Quote Originally Posted by Featherless View Post
    Hello, are you still rebuilding the stock housings? I can send a core if so, how can I get the address etc. Thank You. Glen
    Hi, I still do them. I'll send you a PM with info.

    Edit. I can't PM you as you have not reached a post limit yet or something. Here is my email.

    Edit Sept 2020: removed email. Please send PM or reply to thread if interested. Thx
    Last edited by jb351; Today at 02:23 PM.

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