20vt not running a heater, Pipe housing UPDATED

Hi Looking for some help I need to replace the plastic water housing ( 3 outlets) so that there is no water pipe off to the heater system in the car. Is there a model from another car that does not have this? see pic I dont want the pipe at the back shown with the arrow but still need the two other outlets front and the one at the bottom.

or does any one make an alloy version of this?

try blanking it off or failing that look at the 8v outlet and see if the bolt pattern is the same :wink:

hi theres 2 options i can think of a 2.0 8v it plactic should fit or a vw sharan tdi it got 2ports and is alloy and should have the same bolt pattern i shouold have one laying around i will check

hey the alloy one sounds a treat then I can polish it. does it still have the sensor mounting, let me know if you have one.

cheers.

After asking about  a replacement housing and keep coming up with dead ends and fitment not being what I wanted. I decided to go ahead and make my own. I thought you may want to see the progress.

I found a couple of places for info if anyone else decides not to run a heat.
http://www.vwmod.com/project/swap3.php

and a site that shows pictures of water housings you have to flick about a lot but there is some pictures of water housings.
http://worldimpex.com/parts/genuine-part-coolant-flange_7403.html

anyway heres how it started. cut the raw alloy to size.


each piece was set on a lathe an faced and drilled out to size with a use of a boring bar.


Hose stop kept in place and chamfer for easy fitting of hose


Plate set up on the mill just having the ends reduced.


Parts made ends shape to fit. Then polished up ready for welding.




Trial fitting before polishing.


All finished and welded up and a final polish.




final item all in place just need to get a gasket cut for it.



Thanks for looking Mk1retro….

I am very impressed mate  

Nice touch for conversion would have been to mount a standard mk1 or mk2 type temp sender housing in place of the MK4 item ? Can i ask how much to produce ?

Cheers.
This is the first bit of machine work I have done since school. but I did have the help of a friend how used to be an engineer and knows all the tricks of the trade.

Material was off cuts from a local metal supplier ?15-?20 ish still have a lot left over.
man hours was the main thing, two of us on and off over 3 days maybe 9 hours total I would say. but done in between work time so no cost, but if I had to pay for somebody else to do it maybe ?100 plus
welding done by a metal company across the road from us, a cost of ?35.

not the cheapest but a very good learning curve and a total one off.

Very cool    But seriously,I like it when bespoke items are made to solve problems, esp when they look that good !!!!!

awsome work

from what i can see engine looks really neat

do you have a build thread?

mike