7/8" Hex brass return caps

Discussion in '6.9L IH & 7.3L IDI Diesels' started by riotwarrior, Jan 10, 2016.

  1. riotwarrior

    riotwarrior Supporting Member Supporting Member

    Age:
    53
    Posts:
    14,743
    Likes Received:
    438
    Joined:
    Sep 19, 2006
    Location:
    Cawston BC. Canada
    Been pondering this since seen first brass return caps made years ago and also since @ADV made his wicked cool 1 piece return caps.

    I checked and a couple feet of 7/8" hex stock is not too expensive.

    http://www.onlinemetals.com/merchant.cfm?pid=19943&step=4&showunits=inches&id=81&top_cat=0

    I figured why not attempt to make some brass caps without return lines. Then add the tubes after and being brass hex it would make drilling accurately simplified due to flats to drill into. Press return tubes in and solder and done.

    So I am first looking into what stock locally would be. Then access to a lathe to either do the machining or have it done.

    There are a few lathes in friends posession so maybe this could be doable.

    It would be simplified more if a 3 or 4 flute mill of the correct size could be found then it would be super easy to bang out caps.

    Time to start measuring up caps.

    Hmm...do I want that step inside or not......

    Hmmm. Will see what is available and report back. So far 3' x 7/8" hex brass stock and some 3/16" brass tubing is well under $100.00

    Hmm....

    Wonder if .....:dunno
     
    Last edited: Jan 10, 2016
  2. subway

    subway be nice to the admin :D

    Posts:
    5,975
    Likes Received:
    350
    Joined:
    Oct 4, 2006
    Location:
    York PA
    I have thought about this as well and thought I could do it with a drill press even with some stops set up. I think it would be hard to get a clean enough surface finish that way though.

    Sent from my SPH-L720 using Tapatalk
     
  3. FORDF250HDXLT

    FORDF250HDXLT The life of an Indian is like the wings of the air Supporting Member

    Posts:
    6,456
    Likes Received:
    1,070
    Joined:
    Dec 27, 2009
    Location:
    Maine & Oklahoma
    some of you guys are having a lot more issues with return lines than i am........knock on wood.LOL
     
  4. dunk

    dunk Dunce

    Posts:
    991
    Likes Received:
    0
    Joined:
    Oct 25, 2013
    Location:
    NJ
    While I think this sounds like a nice idea and the handful someone made are sweet... How are the plastic caps inadequate? Do they get brittle and crack? I thought the problem with leaks/air intrusion was primarily old hard orings and not so much related to the caps themselves?
     
  5. riotwarrior

    riotwarrior Supporting Member Supporting Member

    Age:
    53
    Posts:
    14,743
    Likes Received:
    438
    Joined:
    Sep 19, 2006
    Location:
    Cawston BC. Canada
    Blessed I am with return caps that work well.

    However with that said seeing as I am working towards resealing my good remammed 7.3 and doing some mods I would like a custom touch and brass hex return caps would be a sweet addition. Slightl6 champhered like nuts they would look really sharp and one would never have an issue with a cap failing hopefully.

    Thats all...just a really nice sharp looking setup is all that does indeed perform well.

    Nothing more nothing less.
     
  6. crash-harris

    crash-harris Breaker! Breaker!

    Posts:
    2,025
    Likes Received:
    59
    Joined:
    Nov 18, 2011
    Location:
    Chillicothe, OH
    Would indeed look cool, and reusable. I doubt the return system sees enough pressure to crack brass. Same with heat, being brass and all, but what about corrosion?
     
  7. IDIoit

    IDIoit MachinistFabricator Supporting Member

    Posts:
    12,049
    Likes Received:
    1,444
    Joined:
    Aug 26, 2014
    Location:
    commiefornia
    polish em up and coat em!

    i would do this on a lathe, if i had one.
    i would not attempt this on a drill press.
    unless your drill press is a press/mill combo.

    lathe is the tool of choice.
     
  8. crash-harris

    crash-harris Breaker! Breaker!

    Posts:
    2,025
    Likes Received:
    59
    Joined:
    Nov 18, 2011
    Location:
    Chillicothe, OH
    Man, if I had the "expendable" income..my father does have a milling machine in the blacksmith shop...

    I've been itching to use to correctly.
     
  9. riotwarrior

    riotwarrior Supporting Member Supporting Member

    Age:
    53
    Posts:
    14,743
    Likes Received:
    438
    Joined:
    Sep 19, 2006
    Location:
    Cawston BC. Canada
    Ok let me get this right....corrosion...brass....fuel....did you really just ask that question...really?

    Better check out that float in your fuel tank...then inspect the fitting into IP and return fitting from Ip oh ya the return fitting at filter head and the brass fitting at the back of engine where return lines connect to chassis return line....

    Really did you really ask that question?

    Just checking to make sure....:rotflmao

    This is what I can access immediately to make caps
    IMG_20130610_193204_937_zpsef03689e.jpg

    IMG_20130610_193211_238_zpsce907316.jpg

    Can hqve that in shop in week or two if need be...:D

    Think that need became be!:sly
     
    Last edited: Jan 10, 2016
  10. FORDF250HDXLT

    FORDF250HDXLT The life of an Indian is like the wings of the air Supporting Member

    Posts:
    6,456
    Likes Received:
    1,070
    Joined:
    Dec 27, 2009
    Location:
    Maine & Oklahoma
    the only stupid questions are the ones unasked.no ones going to make fun of you for asking questions here.im gunna tell Gary!:D
     
  11. riotwarrior

    riotwarrior Supporting Member Supporting Member

    Age:
    53
    Posts:
    14,743
    Likes Received:
    438
    Joined:
    Sep 19, 2006
    Location:
    Cawston BC. Canada
    True be dat...I am sorry
     
  12. IDIoit

    IDIoit MachinistFabricator Supporting Member

    Posts:
    12,049
    Likes Received:
    1,444
    Joined:
    Aug 26, 2014
    Location:
    commiefornia
    i make fun of this tin foild hat wearin freak all of the time.


    Al, that press isnt bad, but you notice the .002 on the base?
    thats .002 that these things seldom hold.
    i have a few of these, and it will work great if you lock it down and dont move it.
    start dialing and BAM
    remember .002 on a diameter is actually .004
     
  13. riotwarrior

    riotwarrior Supporting Member Supporting Member

    Age:
    53
    Posts:
    14,743
    Likes Received:
    438
    Joined:
    Sep 19, 2006
    Location:
    Cawston BC. Canada
    Get 4 flute cutter rigjt size...bam..machine to depth...bam..next...n so on...or go to Guy's place @Bigredcrew and maybe we can do a few sets on his lathe

    Options....fella has to have options.
     
  14. Clb

    Clb Another old truck Supporting Member

    Posts:
    3,311
    Likes Received:
    263
    Joined:
    Mar 1, 2013
    Location:
    nannyfornia
    With the mill/ lathe chucked up TRUE its all good.
    Question is whats the tollerance for the interference fit on the o - rings, and can it be held by the machine?!
    Good start!
     
  15. OLDBULL8

    OLDBULL8 Good Morning Ya'll. Supporting Member

    Age:
    90
    Posts:
    9,923
    Likes Received:
    322
    Joined:
    Feb 12, 2009
    Location:
    Delphos , Ohio
    I did a measurement on the caps a couple of years ago. I wouldn't know how to search for it now. But there is a step at the top, that's what makes them snap on the last ~1/4" pushing them on.
     

Share This Page