Death Pipe remanufacture in Stainless Steel. Hopefully now available.

Phil_B said:
View attachment 114758

Ok, so having spoken to Andy, it is highly doable.
I haven't proposed making it flexible yet. Been discussing other things:
The pump end has a specific seal. Is this available separately?
The clip that holds 30 into 29 above. He needs one to ensure it works. Is this available? Or anyone have a spare? I have a spare thermostat housing I can send him.
Stainless/plastic mix is not a problem. He has replaced this material pipe before.

He would rather a bulk order, and have one person responsible for distribution than deal with him directly at the moment.
If this runs into hundreds of units, he will deal with orders himself.

Any questions anyone???
Click to expand...
Does it need to be same, rather complex shape, circular at each end, but rectangular in the middle, (to fit in it's alloted space)? More complex shape = higher fabrication cost. I have no idea, does anyone else?
Mac.
 
PlasticMac said:
Does it need to be same, rather complex shape, circular at each end, but rectangular in the middle, (to fit in it's alloted space)? More complex shape = higher fabrication cost. I have no idea, does anyone else?
Mac.
Click to expand...
agreed Mac, circular could make it cheaper as various SS pipe sizes are readily available.
 
I will see if how much I can see of the one fitted to my car, see if the flat bit can be eliminated. I am also happy to be test pilot.

The 2 pegs/pins on the flat part of the pipe. Are they used on the Audi engine???
 
AndyP said:
I don't know the part well as I don't have an FSI, but could a 3D printed part be a cost effective alternative? It may not have the same longevity as s/s, or even the original, but I'm guessing it would be a lot cheaper to produce.
Click to expand...
The problem with that would be the layers, most 3d printed plastic deforms at 90 degrees and even worse most absorbs moisture and breaks down!
 
I would also be interested, price dependent.
I believe the flat section in this pipe is to create turbulence in the coolant, to avoid lamina flow.

Sent from my SM-N960F using Tapatalk
 
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Jellybean said:
I would also be interested, price dependent.
I believe the flat section in this pipe is to create turbulence in the coolant, to avoid lamina flow.

Sent from my SM-N960F using Tapatalk
Click to expand...
Any idea where that information, on creating deliberate turbulence, can be found? It's very important, if correct.
I'd just assumed it was that shape to allow it to fit, in one of the part's applications across the VAG range.
Mac.
 
PlasticMac said:
Any idea where that information, on creating deliberate turbulence, can be found? It's very important, if correct.
I'd just assumed it was that shape to allow it to fit, in one of the part's applications across the VAG range.
Mac.
Click to expand...
This is why Andy asked about the shape and fitting. I said the the bit in the middle was a cable clip mount.
He also asked about the 2 "nipples" on the flat surface.
The narrower part is too long to create the venturi affect though I think.
 
Phil_B said:
This is why Andy asked about the shape and fitting. I said the the bit in the middle was a cable clip mount.
He also asked about the 2 "nipples" on the flat surface.
The narrower part is too long to create the venturi affect though I think.
Click to expand...
Is the cross sectional area, of the rectangular section very different from that of the circular section?
It would seem odd, to me anyway, to create a deliberate restriction in the circuit, if it is.
Mac.
 
Hi Mac, restrictions in the cooling circuit are not uncommon. I once came across a brass restrictor in an RX8 without which it would overheat. I did not believe it at first but that was the case.

Somehow I doubt it would make any difference on this car. I suppose if the dimensions/volume is kept the same give or take it would function ok. Maybe it is down to the manufacturing tools at the production line or similar.

There was someone on ebay called "Malweld" that does custom aluminium fabrications of all sorts. I asked him to do the "Y" piece right after the thermostat to fit my aftermarket hoses. He disappeared and never responded. Maybe if someone calls him from the UK he would take up on this job. Seems simple enough given access to the right tools.
 
Evripidis said:
Hi Mac, restrictions in the cooling circuit are not uncommon. I once came across a brass restrictor in an RX8 without which it would overheat. I did not believe it at first but that was the case.

Somehow I doubt it would make any difference on this car. I suppose if the dimensions/volume is kept the same give or take it would function ok. Maybe it is down to the manufacturing tools at the production line or similar.

There was someone on ebay called "Malweld" that does custom aluminium fabrications of all sorts. I asked him to do the "Y" piece right after the thermostat to fit my aftermarket hoses. He disappeared and never responded. Maybe if someone calls him from the UK he would take up on this job. Seems simple enough given access to the right tools.
Click to expand...
The restrictor could be to keep the flow rate low enough to maximise the amount of heat it takes up. If flow is too fast, heat take up is reduced, (same, but in reverse, goes for radiators in home heating, high flow, low heat output). The complex shape, (difficult to achieve with injection moulding), of our pipe shape doesn't, for me, fit that purpose though, and it's used across several VAG models, with differing cooling systems, but you never know I suppose.
Mac.
 
Just Googling images, the flat section, with the nipples, doesn't seem to have any purpose when install on an A2 FSI. Can anyone confirm this?
Guessing @chumsofmanutd have installed more than any other member.
Mac.
 
Update. Message from Andy:

I could calculate the flow rate by the cross sectional area ! And by doing this make the diameter to suit and have the 2 ends the same for correct fittment
 
Ignoring the pipe wall thickness (1mm??) the bottom line is a 5.7% loss of cross sectional area along the flat run.

Hardly worth worrying about I think.

Andy

(First calculator I came across, I did check the figures from scratch - painfull memories.

www.omnicalculator.com

Segment Area Calculator

With our segment area calculator you can find area of a segment given the central angle or segment height.
www.omnicalculator.com www.omnicalculator.com

)
 
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Andrew said:
Am I being thick but the flow rate of the pump that matters, removing the flat for round just increases the coolant volume in the system by a little, and also the pump flow rate is dictated by engine revs anyway!

Andy
Click to expand...
I'm with you Andy. Having read your earlier post, and wishing I'd read it before, I agree with your thoughts completely.
There are obvious variables, as you say, most significantly, engine/pump speed. Then there's two very different flow paths, depending on the state of the thermostat.
The two flow circuits, the always open, small circuit, (head, heater matrix, etc) , and the large circuit, (engine block recirculating only/engine block via radiator).
Really can't see a slight change in size and shape of a short pipe has any significance, other than a packaging requirement, in another application.
Any alternative material replacement should, (imo), be designed to be the least complex shape, to minimise cost, and to match the cross sectional area of the two circular sections, within +0% to 10%, (acknowledging your calculations).
Mac.
 
I've just checked on 7zap, and it turns out that the 1.6 BAD FSI death pipe is exactly the same part number for the 1.4 AUA and BBY engines. That part number is 032 121 065 D so this part would be useful for those engines too, and may help to increase the order quantity. See here:

Cooling System - BAD engine

Cooling System - AUA and BBY engines

I recently changed this pipe and thermostat housing on our AUA 1.4, and the end of it where it goes into the water pump housing was falling to bits (possibly not surprising after 155K Miles and 23 years of service).

The flat bit on this pipe is necessary on the AUA and BBY engines, because it passes between the crankcase breather oil separator and the engine block. This probably keeps it warm, and may prevent condensation in the separator? On these engines, you have to take off the oil separator to change the pipe.

When I changed mine for a new Audi one, I would have definitely gone for one of these instead if it had been available. So in summary, I just wanted to say that the weird shape actually makes it applicable to a lot more applications.

On another note, the O-ring seal at the water pump end of this pipe is available separately, under part number 032 121 665 A.
 
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Mark Adams said:
I've just checked on 7zap, and it turns out that the 1.6 BAD FSI death pipe is exactly the same part number for the 1.4 AUA and BBY engines. That part number is 032 121 065 D so this part would be useful for those engines too, and may help to increase the order quantity. See here:

Cooling System - BAD engine

Cooling System - AUA and BBY engines

I recently changed this pipe and thermostat housing on our AUA 1.4, and the end of it where it goes into the water pump housing was falling to bits (possibly not surprising after 155K Miles and 23 years of service).

The flat bit on this pipe is necessary on the AUA and BBY engines, because it passes between the crankcase breather oil separator and the engine block. This probably keeps it warm, and may prevent condensation in the separator? On these engines, you have to take off the oil separator to change the pipe.

When I changed mine for a new Audi one, I would have definitely gone for one of these instead if it had been available. So in summary, I just wanted to say that the weird shape actually makes it applicable to a lot more applications.

On another note, the O-ring seal at the water pump end of this pipe is available separately, under part number 032 121 665 A.
Click to expand...
Are the nipples used in the AUA & BBY applications? Or just the flat section for clearance?
Mac.
 
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