I thought of posting this in the 1st gen section, but then i realized that very few 1st gen owners have done the following mod. I figured I might get better input in this section. The long and short of it is that I did a 2nd gen oil cooler conversion 3 years ago on the 1st gen (see avatar on left). Originally, the oil cooler sat below the radiator. The 1st gen oil coolers have problems leaking at the bungs. After fixing the oil cooler numerous times, I went for swapping it out. The 2nd gen oil cooler now sits in front of the radiator. This, however, called for different oil cooler lines. The 2nd gen lines unfortunately were not long enough. I took them to a local hydraulic shop and for about $60 or so, I got what seemed to be "new" lines that fit perfectly. I was under the impression that it was a permanent fix. Fast forward 3 years, and the line coming out of the front side of the engine blew off without warning. Turns out the way they made them wasn't exactly the best way. They use all the old fittings and used hydraulic hose and used new sleeves and compressed them over the barbed ends. The problem was that the hose blew off with the sleeve still attached. Usually, the sleeve is completely attached to the fitting so that this could never happen. It was also hydraulic hose, not like the factory rubber braided lines.
Fortunately, it wasn't a total loss. I lost all 5 quarts of oil and the engine was spared (surprisingly!). I just need to find a fix for the lines. (Unfortunately, the turbo didn't like the lack of oil. It'll need replacing...)
So, either I spend about $250 to buy Russell or Earl's fittings and hosing, or I can do something else permanent with what I have. Are there any permanent options out there that won't cost soo much? The only other option I can think of is to use all the existing fittings (they have barbed ends which are about or over an inch long), find and buy high quality, high temp, high pressure RUBBER hosing (the previous hydraulic lines had a plastic inner liner that slipped) and high quality clamps to keep everything in place. I would expect the rubber lines (with clamps) to have a far better hold on the factory fittings.
Comments or suggestions please?
Thanks

 

A good friend of mine pointed me in the right direction today. I was able to get some 1/2" hose from Napa that withstands 500*F and 350 psi and can be used for petroleum. That, along with doubling up on all the clamps, I was able to get it all done for $45 - and saved $200.

 

My experience is from racing.

I had what you describe happen using Aeroquip push lock hose. The hose swelled up (from heat) slipped off the fitting. Killed a good engine. In the distant past I used rubber oil hose, hose clamps and barbed ends on oil cooler on a Mustang . Had one of the hoses come off (also on a race track). So that would not be my choice.

After my push lock hose failure I switched to all braided steel lines. It was expensive but not sure if it was $250. I'm thinking the number was closer to $150 or so to replace everything with braided steel. I run two OE oil coolers on my race car so I had to replace twice as many lines. I look at braided steel lines as necessary it you want more of a "forever" fix.

The thing you have to consider is that the oil coming out of the engine is hot, really hot. Some of reported temps as high as 300 degrees going from the engine too the cooler. So a plain rubber hose.....man I just don't know about that.

 

Never use push lock fittings for engine oil pressure!

 

I think the notion that $250 spent on oil cooler plumbing is to expensive is nuts. In the event of a failure your looking at likely engine and turbo damage. But, depending on what's happening when it gives out, it could be a lot worse. Oiling down your tires could result in a major crash and a total loss of the car. And really you could lose your life or cause harm to others.

Whenever you are taking on this type of engineering projects, I think it is best to look at the most robust solutions and not cut corners.

Look at how it's done on actual race cars and follow their lead.