Death Pipe remanufacture in Stainless Steel. Hopefully now available.

rotifer II said:

Thermostat housing​


If you have time @indy tackle the thermostat project its a great brain work out.
Create a new thread and share your journey.
@Evripidis could also start the same project at the same time.
Once you have both individual designed your work without sharing any ideas between you.
Swap your projects with each other and refine them and now collaborate to make the final prototype design plans.
Click to expand...
I'll need to get an FSI thermostat as I'd need one not in situ on a car, and its not the same as the damaged 1.4 thermostat I have on hand unfortunately.

wrong Indi :)
Though we both apparently have crystal Blue A2s
 
I too am following this thread with interest, and would also be more convinced by an aluminium replacement than by stainless (arguments stated above by @Indi while I was typing) - the practical aspect of insertion blind into the water pump does not advocate for a rubber hose with two sprouts at first glance. And I respectfully disagree with point 2 as stated by @Evripidis: the catastrophic failure of the "death pipe" in itself is a problem, not only the combination, as slowly developping failure is not handled the same as a bursting blind pipe and does not entail the same consequences, so a (preferably aluminum) sturdy replacement of the Audi 032 121 065D pipe would make sense to me.

As for the ageing of the thermostat housings weakness, I still see this as inherent with time+heat+plastic, even if fiber reinforced for the quality parts. I suspect that the non circular section of the seal ring is not a lunacy from the manufacturer but rather aims at enhancing longevity of sealing by exerting a more constant pressure under displacement and distorsion than a round o-ring would (more non linear spring effect from the round section).
Also, the inserts in thermostat housings appear to me as failure points (stress concentration), and using/making flanges to spread the compression load over a wider area so as to applying it to both sides would limit deformations which contribute to sealing failures over time (my quickfix was to use washers so that the inserts are not mostly subject to sheer).
 
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Is it's time for a workers co-op?
The A2OC menders and makers
I have a pen and paper at the ready. Could be a totally new forum heading,
Just ideas.
EDIT
For example look up the hi-viz jacking points for a successful project.
 
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Great find @Evripidis

Capture.JPG

£23.57 each for the pipe in stainless steel?
Cannot work out postage the website is too difficult even when using translation.
 
Might be worth asking them about the A2 BAD Thermostat housing?
They seem to have the required expertise and experience.
Mac.
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Should we start a new thread? I can try and contact them but would be relying on a translate App, things may get lost in translation.
Anyone have multi linguistic skills or know how to speak Ukranian?
 
rotifer II said:
Hi Mac,
Did you order one?
Click to expand...
No, I've said my interest is A2OC based,both pipe and housing.
I'm not keen to do anything major to mine until cam belt change next year.
The death pipe failure is often, I believe, down to ignoring the EML. I think the sequence is that there is a failure in the cooling system controls, the heater in the thermostat capsule, or insufficient temperature drop across the radiator, cooling fan, etc. A permanent EML is triggered, but ignored, so the engine is permanently running at around 110C, regardless of engine speed and load. Heat builds faster than the cooling system can dissipate it, thermal runaway ensues. That's what causes the plastic parts to fail dramatically. Ignoring EML, and a reluctance to use the OBD diagnostics is the biggest FSI killer. Death pipe failure is a consequence of ignoring warning signs. A human failing, and most common in males.
Mac, (in a philosophical mood today).
 
rotifer II said:
Should we start a new thread? I can try and contact them but would be relying on a translate App, things may get lost in translation.
Anyone have multi linguistic skills or know how to speak Ukranian?
Click to expand...
Good Evening,

I would bet that our member 'Ukrainian' speaks Ukrainian quite well :).

Andy
 
Maybe the sprout can eliminate one of the 'T' or the 'Y' junctions leading to the matrix a bit further up the coolant path. Not sure which though.

Still doing trials on mine but; interesting website nonetheless, I hope they can deliver.
 
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