Thought I'd post a "build" on making a Water Passage/Crossover for a 331 HEMI. I had posted a want ad for a stock water crossover on this and other forums for quite a while and not having gotten any responses, decided to try my hand at making one. (must add that a fellow HAMBer offered one for sale later on, but as I was well into making this, decided to follow through) Some 90º & 45º 1 1/4" "weld-els" from McMaster-Carr, a piece of 1 1/4' tubing and a few plasma-cut parts were used to make it. Even though those els are expensive, I wanted this to look "factory" One difficulty in designing this was that the LEFT head sits 7/8" ahead of the RIGHT. SolidWorks was used to model it along with a welding fixture. The side flanges were left long to provide mounts for accessories if needed. SW Model + Weld Fixture (not shown is a top plate that locates the thermostat housing flange)... Initial fit-up; sans bolt bosses.... welding completed, with bolt bosses added....the bolt holes were placed after the welding was finished; yes, it did move a bit. recheck fitting, trial fit generator/alternator mounting bracket and primer paint make sure bypass hose fittings align as intended... 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Well done! Did you compensate for the offset head surfaces by adjusting the 90 degree elbows? Where did the thermostat housing flange come from? Thanks, Gary
thanks for the compliments The 7/8 offset was almost entirely done by swiveling the 45º elbows, one forward, the other back; however, the faces of the 90º elbows that join to the 45º els are sitting at 89.5º relative to each other (rather than at 90). Once the basic design was established, the parts were made, then placed in the weld fixture, which was also designed at the same time. Some tweaking was done to get the final fit mainly because the weld-els are not exactly per spec. The thermostat housing is a 2-piece weldment. The flange portion is a plasma cut part and the neck is tubing. The housing was welded into the top tube and then the holes were tapped. Here's what had to be done to the upper tube to allow for the housing.
The Jalopy Journal
