Fuel cooler for regulated return system
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Logistics Pro
Joined: Aug 2005
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From: Morgan Hill, CA
Fuel cooler for regulated return system
What if anything are you guys running for a fuel cooler? I'm going to put in an oil cooler from a 1986 Mazda RX-7 as my cooler. Last summer the tank would get pretty hot from all that fuel going through the heads and back. I think the newer vw's are running a cooler because they have a similar layout. I don't think the pump likes working with all that hot fuel. I think the fuel is supposed to cool the pump a bit.
Anyway I got the cooler for free from the race car builder next door. He's downsizing and had an extra one and I do some machining for him from time to time. He uses them on his 700 hp, 2000 lb Porsche powered racers. He says they are very efficient. He learned his trade in England and worked for McLaren building cars for a while so I know I got a good part to start with. It's kinda beat up but he swears it does not leak. I'll find out soon enough on that.
Here's a couple of pics of what I am starting with.
Anyway I got the cooler for free from the race car builder next door. He's downsizing and had an extra one and I do some machining for him from time to time. He uses them on his 700 hp, 2000 lb Porsche powered racers. He says they are very efficient. He learned his trade in England and worked for McLaren building cars for a while so I know I got a good part to start with. It's kinda beat up but he swears it does not leak. I'll find out soon enough on that.
Here's a couple of pics of what I am starting with.
Lead Driver
Joined: Oct 2004
Posts: 7,413
Likes: 1
From: Columbia, MO
I've started kicking this idea around as well. Diesel fuel supposedly loses some of it's kick as it gets hot, and that the prime operating temperature for diesel fuel is between 80-100* F. I'm sure the fuel temp coming out of the regulator, on an externally regulated system like yours, is higher than that. Do you plan to install it in the feed line before the heads, or on the return line to the tank?
Post Fiend
Joined: Feb 2006
Posts: 11,892
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From: Middle Tennessee
I hadn't thought about that. I assume this wil be mounted in the return line between the engine and the tank if I read you right. Sounds good to me and being in Ca I don't think you have any freezing problems. Now I gotta put a temp gauge in my fuel tank.
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Logistics Pro
Joined: Aug 2005
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From: Morgan Hill, CA
I've heard that our trucks with a system like mine will produce a 160 degree temp in the tank after a few hours. I plan on putting it on the return side between the engine and the tank. I'd like to use some quality fittings and lines, but am not totally sure on how to connect to the factory system on both sides. I'm not sure where I want to mount it, if I want to add a fan, etc. I'll have to look at what kind of room I have in the front. It'd be nice to have real air flow through it. Maybe I can machine a new lid to the tank and have decent connections there. I'm really open to ideas at this point as you might be able to tell.
Lead Driver
Joined: Oct 2004
Posts: 7,413
Likes: 1
From: Columbia, MO
I'm wondering if I couldn't use my stock transmission cooler as a fuel cooler. Since I'm having my stock trans cooler replaced with a larger 6.0 unit next week, I'll have my stock one left over. I'd mount it under the truck, behind the transfer case out of the way of any road debris. My concern is does the factory trans cooler have any sort of thermostat in it, or any sort of bypass valve?
Post Fiend
Joined: Jul 2005
Posts: 14,582
Likes: 12
From: 21791
i do not know if this is allowed, but i have a link to a thread on TDS that has to deal about fuel coolers. i know it is another competing site and i shouldn't do this, but it helps discussion. i went there originally to find pics of BlackWidow Puller's fuel cooler, but i found this first and figured it would work.
here is the link: Cat=0&Number=2911746&an=0&page=0#Post2911746
if mods do not approve of this, delete it. it also said Dieselsite sells fuel coolers.
here is the link: Cat=0&Number=2911746&an=0&page=0#Post2911746
if mods do not approve of this, delete it. it also said Dieselsite sells fuel coolers.
Hotshot
Joined: Jan 2002
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From: La La Land
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Post Fiend
Joined: Jul 2005
Posts: 14,582
Likes: 12
From: 21791
damn. i posted a post a while ago and i got the infamous message where it doesn't show up. i found a great fuel cooler thread on another board and i was wondering if it can be posted here. it's good for the discussion.
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Lead Driver
Joined: Oct 2004
Posts: 7,413
Likes: 1
From: Columbia, MO
Thanks Pop. The only think is I thought there was a bypass valve in the stock cooler, from a while back and someone was asking which tru cool to get - with or without a bypass? I was thinking that someone mentioned the stock trans cooler having a heat controlled bypass. Maybe not though.
Kris, I think I know which one you're talking about. If it's the same thread I'm thinking of, nearly the same question I asked above got posted over there too.
Kris, I think I know which one you're talking about. If it's the same thread I'm thinking of, nearly the same question I asked above got posted over there too.
Lead Driver
Joined: Jun 2003
Posts: 8,298
Likes: 25
From: Damon (South East Texas)
Dieselsite offers a fuel return cooler kit that has a built in thermal bypass. The bypass on the transmission is not on the cooler itself, but is a line that connect the trans cooler line ports together on the trans. This regulates the temp of the oil until it is hot enough to flow completely thru the OTW and OTA coolers.
Lead Driver
Joined: Oct 2004
Posts: 7,413
Likes: 1
From: Columbia, MO
Thanks mueckster. I didn't know it was an extra line. Wonder if I could use it if I turn the trans cooler into a fuel cooler. My concern is getting fuel too cold in the winter, gelling in the cooler, and plugging the return line. It wouldn't be a concern once the engine is up to temperature, but until then, I'd be a little worried. I guess I could make my own bypass with some valves that would be for use in the winter.
Lead Driver
Joined: Jun 2003
Posts: 8,298
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From: Damon (South East Texas)
I looked again at the cooler that Dieselsite offers. I believe the thermal bypass is part of the cooler itself. I think the bypass on many other trans coolers is thru the sizing of the flow passages. I don't how this would work with diesel fuel of a much thinner viscosity. Unless, it is sized specially for the diesel fuel.
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Thread Starter
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Logistics Pro
Joined: Aug 2005
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From: Morgan Hill, CA
After looking long and hard at the bottom of the truck I am starting to lean towards using one or two of these. This one is 30 inches long and is about $65. The RX-7 cooler most likely would work better, but trying to find a place to mount it with actual airflow is tough. The long straight ones like this would be easy to mount along the frame.
