Finally Going Single! Part 2 by cohbra

3-5-2011

I bought the tubing at www.anfittingsdirect.com which was $14.99 (great prices on aluminum tubing by the way) http://www.anfittingsdirect.com/shop...7fed0522fff6b9

...and the threaded cap at www.mofoco.com (slightly different version in the link than the one I used) for $11.99

http://www.mofoco.com/item/EMPI_8904...On_Cap/341/c78

As far as the flange goes, I had some 1/4" aluminum plate around that I got out of a scrap bin at a previous job. I made it with a roll of painters tape, (to get the pattern) a cordless jigsaw & drill with a decent hole saw kit, a can of WD-40 for lube, and a grinder with some 3M pads. Of course you will need a tig welder to weld it up, but I literally have about $27 in parts (not counting shipping) into this thing and honestly about 4 hours worth of work at the most.

If you want to do this sort of thing, the best investment you can make is a tig welder and some time. Do some reading (or take some classes) and teach yourself how to tig weld. For me it is like meditation, I could spend all day in the garage tig welding and walk out with a big smile on my face. That is, as long as I have good ventilation. I made that mistake once and felt like I had the flu for the next week. Not good.

Done

Water neck welded onto the thermostat housing. 

Partially cleaned up and drilled/tapped the hole for the water temp sensor. 

All polished up. I think this might be one of the prettiest parts I've ever made.