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I wanted the benefits of a bypass for my coolant filter without the extra hoses and T's, so I drilled a bypass passage through the filter mount. The bypass consists of 2 5/16" holes (see picture below). The main bypass hole hole runs diagonaly from the bottom just missing the center nut to the outlet. The second hole is straight through inlet (at the bottom) to the first hole to allow for easier flow. I also used a 3/8" bit to clean up the hole in the bottom. The main bypass hole could probably be 3/8" but for the second hole 3/8" would probably be too big.
I'm not sure what you're trying to accomplish. If you're going to use a standard water filter, it already has a bypass built in. Cut one apart and you'll see what I mean. There will be a hole in the end plate.
PS:
If I remember correctly, FORDF250HDXLT has his set up to filter all of the coolant flowing through the heater circuit. When it gets plugged, his heater output cuts down. After a couple filters the system should be cleaned up.
Well in reading about coolant filters there seem to be two views: one that wants the filter as a bypass to the heater core for maximum flow through the heater and one that just puts it inline and changes the filter when it gets clogged. This was simply an attempt to get the benefits of both (a clean install with high flow throught the heater core). The hole in the filter mounting fitting is only 3/16" which is fairly restrictive in itself even if the filter is clean.
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