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Old 04-12-2013, 01:02 AM   #1
V8 GTFO Lesbic WGN
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Default ELH Install: need to flare Cooler hard line, typical flaring tool does not fit (pics)

Doing a ELH install on a FXT '07, Oil Cooler hard lines interfere with header, long hard line has been shorten to clock the Oil Cooler and allow clearance to header and timing belt cover.

Since line has lost the flared end a new is needed, problem is typical wing nut flaring tool does not fit as it hits the cooler body, looking for ideas to flare up the end of the line?? Compression fitting, brazed fitting, other?





1. Compression fitting link McMaster SS fittings?





2. Brazing fittings? Is there brazing solder for steel?

3. Other???
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Last edited by V8 GTFO Lesbic WGN; 04-12-2013 at 10:11 AM.
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Old 04-12-2013, 01:34 AM   #2
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you could do a weld bead or even just some tacks.

could also heat and mushroom the end with a cone shaped punch.
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Old 04-12-2013, 10:52 AM   #3
V8 GTFO Lesbic WGN
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^Good tips sir, I will try your suggestions if the fittings or flaring don't work.

Last edited by V8 GTFO Lesbic WGN; 04-12-2013 at 12:23 PM.
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Old 04-12-2013, 01:30 PM   #4
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you can count out option 1. There is definitely not enough tubing left on the end to fit on the compression fitting. And just to validate my claim, I am a mechanical technologist that uses compression fittings on a daily basis.

option 2, you can do this. You can braze steel (or stainless... the cooler kind of looks like it) with brass. You could even braze on a brass barbed fitting if you can find one with a snug fit.

option 3... Super handy piece of info, AN fittings (typically made with aluminum) are the MIL spec version of JIC fittings (typically steel). You can get weld on JIC fittings like these:





If you can tig weld this would probably be the best option. If not, getting it welded on should be cheap as it is such a small piece it should take almost no time. and everybody likes AN fittings on cars...

A "better engineered" option would have been to make the header fit in the first place.
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Old 04-12-2013, 02:25 PM   #5
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The other option, would be to put the 37 JIC Flare on the end of the oil cooler, with the nut and sleeve, and use a female style hose fitting.
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Old 04-12-2013, 03:25 PM   #6
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^That's option 1, Zegy says not enough room, although I don't see why not, I have at least 1/2" of straight tubing left in the elbow.


Last edited by V8 GTFO Lesbic WGN; 04-12-2013 at 04:13 PM.
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Old 04-12-2013, 04:20 PM   #7
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Quote:
Originally Posted by V8 GTFO Lesbic WGN View Post
^That's option 1, Zegy says not enough room, although I don't see why not, I have at least 1/2" of straight tubing left in the elbow.

no option 1 is a compression fitting, hes saying flare the tubing to 37deg. but i thought you said you didnt have enough room to put a flare on it.

i would tig it up and call it a day.
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Old 04-12-2013, 04:50 PM   #8
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Quote:
Originally Posted by V8 GTFO Lesbic WGN View Post
^That's option 1, Zegy says not enough room, although I don't see why not, I have at least 1/2" of straight tubing left in the elbow.

you're welcome to try but i guaranty you there will not be enough room. Taken from the swagelok installation manual:



Now these measurements are a little excessive but not by much. As you can see 1/2" is not nearly enough for a compression fitting.

+1 PARANOID56... Easiest and reliable.
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Old 04-12-2013, 05:39 PM   #9
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weld a bead around the end and you're good to go. anything else is over thinking it. It doesn't take much to retain a coolant hose. Use a real clamp not those factory spring clamp and you'll be fine.
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Old 04-12-2013, 06:29 PM   #10
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Thank you guys I am really enjoying this thread, I guess will tig it up problem is finding a tig welder in this one horse town.
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Old 04-12-2013, 06:49 PM   #11
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i would do it for free if you happen to be near the Philadelphia area, but it doesnt seem like that from your profile.
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Old 04-12-2013, 06:51 PM   #12
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You'd also be fine brass brazing or soldering it with something like 50/50 tin/lead solder with a propane or map torch. It doesn't need to be perfect or pretty, just a ridge to retain the hose. There isn't that much pressure in a cooling system.
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Old 04-17-2013, 11:40 AM   #13
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Still looking for solution, thinking a butt weld socket elbow with single barb fitting on other end would be the best solution, just can't seem to find one, something like this but is missing the single barb at one end.

The OD of the Oil Cooler fitting is approx 1/2" (12.7mm).


Last edited by V8 GTFO Lesbic WGN; 04-17-2013 at 12:29 PM.
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Old 04-17-2013, 08:08 PM   #14
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If the line is not an odd size get the ferrule out of a compression fitting slide it onto the end of your steel line and silver solder or braze it on. This will create a nice smooth barb to hold your tube.
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Old 04-17-2013, 08:46 PM   #15
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Great idea a female 1/2" fits but the brazing does not hold up, will have to tig it.

Last edited by V8 GTFO Lesbic WGN; 04-25-2013 at 10:59 PM.
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Old 04-25-2013, 10:59 PM   #16
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I ended up having a local welding shop tig up the original flared tip section.



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Old 04-26-2013, 09:30 AM   #17
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Why didn't you just ditch the oil cooler all together?? If your at the point to gain power your going to an equal length header. Then the stock oil cooler is most definitely obsolete.

In all reality IMO its pointless to begin with
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Old 04-26-2013, 12:01 PM   #18
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Quote:
Originally Posted by dangerousatom View Post
Why didn't you just ditch the oil cooler all together?? If your at the point to gain power your going to an equal length header. Then the stock oil cooler is most definitely obsolete.

In all reality IMO its pointless to begin with

I agree with this. It's actually been removed from all of the newer Turbo cars besides the STi.
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Old 04-26-2013, 12:19 PM   #19
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^ding ding ding...STi = more power = more cooling needs = hence need for Oil Cooler, regardless of how much cooling it provides it is better than no Oil Cooler.

Last edited by V8 GTFO Lesbic WGN; 04-26-2013 at 12:41 PM.
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Old 04-26-2013, 02:23 PM   #20
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Old 04-26-2013, 05:22 PM   #21
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Quote:
Originally Posted by V8 GTFO Lesbic WGN View Post
^ding ding ding...STi = more power = more cooling needs = hence need for Oil Cooler, regardless of how much cooling it provides it is better than no Oil Cooler.

I actually think it is because they haven't made an changes to the EJ257 in a long while and they are riding that relatively low volume platform out to the end (this year) of the GR platform. The EJ255 seems to be a higher volume runner and probably worth the costs to change it over to no cooler.

Just a guess. I still don't think that tiny factory cooler does much of anything, especially for a street car. On any of the really hot Subarus (Spec-C and RA-R), they simply moved to a real oil cooler.
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Old 04-27-2013, 06:42 AM   #22
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A real oil cooler will not help warm up the oil in cold starts.
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Old 04-29-2013, 05:40 PM   #23
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A real oil cooler will not help warm up the oil in cold starts.
That is correct. But your coolant needs to be at temperature for the OEM cooler/heater to work. And your oil is up to temp usually around the time your coolant gets up to temp as well.

Also, I don't care about cold starts around these parts much.
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Old 04-29-2013, 06:05 PM   #24
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^got a point there but the question is why Subaru would put it in the first place? I have spent over 12 yrs on VA/VEs working for main Tier Ones, GM, Ford, Honda, Toyota, and I know from professional experience cents $0.0X count, if it had no real purpose it would had been removed from the BOM years ago. We spend $1000s validating stupid cent engineering changes, this cooler and ancilliaries is at least $50 OEM cost, that's huge in the overall budget of a program, the bean counters would have smelled this by now and would have eradicate it since bug eye times.

Last edited by V8 GTFO Lesbic WGN; 04-29-2013 at 06:11 PM.
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Old 04-30-2013, 11:34 AM   #25
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^got a point there but the question is why Subaru would put it in the first place? I have spent over 12 yrs on VA/VEs working for main Tier Ones, GM, Ford, Honda, Toyota, and I know from professional experience cents $0.0X count, if it had no real purpose it would had been removed from the BOM years ago. We spend $1000s validating stupid cent engineering changes, this cooler and ancilliaries is at least $50 OEM cost, that's huge in the overall budget of a program, the bean counters would have smelled this by now and would have eradicate it since bug eye times.
I work for a tier one as well and I agree with you on the cost pressures. And they did seem to sniff it out as it has been completely removed from the EJ255's after 2007.
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