After reviewing Beetle’s [You must be registered and logged in to see this link.]
post I have decided to take a crack at it. The photo collage shows the beginning of my efforts. With the goal of trying to simplify the mounting and plumbing a bit, I think I have it figured out as to what AN fittings will be needed at the thermostat and at the cooler.
Basically, the thermostat will be mounted on the frame tube in between the right exhaust pipe and the alternator belt housing. Port 1 - fed from the oil pump will need a 90 degree ORB to -6AN and will connect to a hose with a 90 degree upper end and banjo lower end. (Banjo to -6AN at the port also possible. Pro and con insights are welcome as I have no familiarity with banjo fittings. Any flow issues?) Port 2 - output to cylinder heads, will also need a 90 degree ORB to -6AN, but the hose will use a 45 (or 60) degree end to angle up into the space between the cylinder heads. I am planning on changing out the alternator tensioner bolt to a hex head to allow adjustment without having to remove parts. Port 3 - to the oil cooler, can use the straight -6AN nipple but will need a 30 or 45 degree swivel hose end to allow the hose to clear the right engine mount. Port 4 - from the oil cooler, looks to be a straight shot from below so it will likely be -6AN straight nipple to straight hose fitting. At the cooler I am planning on changing out the reducer bushings to 16mm by -6AN and connecting via straight hose fittings.
Now for the things that I’d like some input on. First, I am thinking of using prefabricated Fragola crimped PTFE hoses for the connections at Ports 1, 3, and 4 because they are compact and reasonably inexpensive, with a short lead time here in the U.S.. The clearance between the thermostat and the cylinder fins is fairly tight and I’m not sure the bulk of a field-assembled connector will do for the fitting for Port 1. Port 2 has a bit more clearance but I might still stick with the Fragola prefabbed PTFE hoses.
Question 1: What size are the banjo fittings at the oil pump outlet and the cylinder head inlets? I haven’t pulled things apart to be able to measure.
Question 2 - for Beetle: How did you route the hoses down at the cooler? It’s looking to me like the hoses from Ports 3 and 4 may need to wrap around in front and under the lower right engine mount and go in at the front of the oil cooler housing.
Question 3 - Any thoughts about fabricating the hose assembly up at the cylinder head? It looks like Guzzi uses a custom welded hardline T section that would be hard to duplicate with AN fittings. A double ended or stacked banjo at the right cylinder head might be a workaround. Clearance issues? Taking the old assembly to a hydraulic shop and having them cut the hose and install a crimped 45 degree connector to get to Port 2 might also be an option, or will the -6AN fittings work with the original hose? (Beetle, how did you do this?) I would prefer to remove and store the original parts so that the bike can be returned to the stack configuration if desired.
Question 4 - Are there any issues with using steel banjo fittings at aluminum connection points, such as at the head or the thermostat? There are some ones with angled tubing and barbs that could be fabricated with crimped sleeves that would make for a much more compact installation. Most of these are listed as fuel or nitrous fittings. Would they have sufficient flow for oil too?[You must be registered and logged in to see this image.][You must be registered and logged in to see this image.]