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  1. #1
    Join Date
    Aug 2010
    Location
    Near Bendigo, Victoria, AUS
    Age
    72
    Posts
    3,102

    Default Tricky aluminium project

    Pam and I have been travelling for the past 3 months in our (15year old) Ford Transit mobile home.
    On the way, a couple of oil changes were due. I had to use considerable force to remove the plastic (PA66-GF30) oil filter cap, which on refitting cracked and leaked.... So I cleaned it thoroughly and repaired it with epoxy. That didn't hold pressure... So I tried to order a replacement, only to find that they are no longer available! Eventually I found an aftermarket one which needed significant filing of the large buttress thread to make it fit.
    I decided to make a new one from aluminium on my return to my workshop.
    It's done now and I'm pleased with the fit and quality.
    I made it out of a piece of flat bar 65mm thick, cutting an octagon on the bandsaw before turning it on the lathe. Finding and grinding a threading tool for buttress thread and setting it all up was achieved without mishap.
    The tricky bit was a set of pegs inside which hold the bypass valve. Difficult to measure, mainly. Eventually I cut the old one in half to understand and measure thicknesses.
    Here are a couple of pics of the progress.
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  2. #2
    Join Date
    Sep 2006
    Location
    Mallacoota,VIC,Australia
    Age
    53
    Posts
    1,010

    Default

    Great job Joe, well done. I'm sure that it last for years.
    All The Best steran50 Stewart

    The shortest way to do many things is to do only one thing at once.

  3. #3
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,444

    Default

    Hi Joe,

    Very nicely done

    My old van didn't have the drain plug on the bottom and I bought an expensive socket to unscrew it to get the thing off and sealed when I put it back on. I hated having to do an oil change on that thing.
    Best Regards:
    Baron J.

  4. #4
    Join Date
    Aug 2011
    Location
    Melbourne
    Posts
    4,779

    Default

    Nice work Joe.

    Hope you and Pam enjoyed your travels. Sounds like you are well set up!

    Simon

    Sent from my SM-G970F using Tapatalk
    Girl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.

  5. #5
    Join Date
    Aug 2009
    Location
    Sydney, NSW, Australia
    Posts
    1,836

    Default

    Wow if that isnt quality i donno what is, must have taking many hours to produce such a job well done two thumbs up

  6. #6
    Join Date
    Oct 2006
    Location
    Newcastle
    Posts
    124

    Default

    Nice work
    Hafco AL320G Lathe
    Toolex RF31 Mill/Drill
    Saber Bandsaw

  7. #7
    Join Date
    Dec 2018
    Location
    NSW
    Posts
    586

    Default

    Looks familiar.
    Is it the 2.2L TDCi donk?

  8. #8
    Join Date
    Aug 2010
    Location
    Near Bendigo, Victoria, AUS
    Age
    72
    Posts
    3,102

    Default

    No, its for our 2.4 l TDDI donk.... identical oil filter though I believe....
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  9. #9
    Join Date
    Apr 2018
    Location
    Drouin Vic
    Posts
    633

    Default

    Great job and vary interesting from where I sit; the Land Rover Defenders from 2008 to end of production had the Ford Transit (Puma) motor, first 2.4 then 2.2L. A cracked oil filter housing in some of the remote outback locations ours has been to is not a pleasant idea to contemplate.

  10. #10
    Join Date
    Dec 2018
    Location
    NSW
    Posts
    586

    Default

    Great choice of vehicle.
    For the apparent amount of work involved in the manufacture of a new oil filter housing, it might be more viable to create a filter relocation plate and associated hoses to move the filter tree, 'cooler and filter proper to a different location.

    I wouldn't be surprised if that cover (plastic) is also seen in other makes of vehicles. I have not measured, but I could almost swear the missus' Hyundai diesel has the same filter cover and filter.
    And in the auto game, where there is lots of models with a non OEM part... there is bound to be variants made out of other materials etc.

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