Hi all.

This might be of some interest to those of us in the wasmer parts of hte world,

A fuel heat exchanger that cools the returning fuel, from the fuel rail just before it is returned to the tank.

Only one test ride so far but a marked reduction in the temp of the fuel in the tank that can be felt at your knees.

On using a laser thermometer on the start of the fuel return line, at the end of the fuel rail, measured approx 60 deg C and at the point where the fuel line returns to the tank only 24 deg C.

I will conduct further tests both with the inlet to the exchanger covered, take a reading of the temp of the fuel in the tank, uncover then immediately re ride the same route with the inlet open and retest.

I will post findings here when completed.

Regards Bushy.



See photos below.



left top, heat Exchanger with "Heat Shield " tubing..... right top, inlet hole cut in radiator cowl.

left bottom, installed exchanger..... right bottom, hole from inside with mounting clips.





Completed project over winter 2011 here in Tassie.

Nice one Bushy, the 'ol Tassie ingenuity coming through there, well done. Just make sure the copper doesn't cop any vibration to avoid work hardening, wouldn't like to see the fuel spraying back towards the hot pipes. Should keep the fuel tank a bit cooler, especially in summer.

Good on you Bushy, really interesting especially because you took measurements, top stuff, well done!
Regards,
K-BIKE

well done bushy .....nice results ...and congrats

Damn good thinking there Bushy it certainly works well but (and there is always a but) how come you used copper and not aluminium was it that copper was what you had

I had the copper in the shed, aluminium would have been easier to turn in the lathe. Soldered the elbows both top and bottom, not possible with aluminium.

Mark II is on the cards, aluminium with turned ends for connection to the hoses. Will add to this post when done.

Regards Bushy.

Thats a good idea Bushy . Used to have a compressor made in India with cooling tubes covered with aluminium washers .......... when the paint came off them discovered they were made from coke cans .... wonder if your system could be used to cool the fuel before it enters the fuel rail to give more bang for your buck

I thought of trying to use it before the fuel rail but since its under pressure before the rail I didn't want to tempt fait with a failure, spraying fuel everywhere, after the rail on the return line, no pressure as fuel is returned to the tank.

I'm just trying to lower the temp of the tank to make it more comfortable during the warmer months of the year.

yep a really good idea bushy ...i noticed last summer ....even just the aircon piping insulation made a huge difference .....went from being in the high 50s to the low 30s ...comparitivly ...but as i idle round town the temp still creeps up .....it would be nice to have a cooling affect as well ..as soon as speed is acheived .

ive got my eye on a after market oil cooler (about 8 mm tubing 3 flat turns in aluminium fins about 6 inches by 3 inches by about an 1 inch thick ) and cheep as ....i had thought of cutting the front radiator fairing like you have, to provide air flow .....i now have a backup original fiber glass bit for experimentation now ....and summers on the way "big time" up here ...



thats way crazy.... hey toto?....trust the indians to use whats around ....inventive ?!!!

Thats first class workmanship there bushy, a job well done.

BIG D

Had the same idea as you Charlie but looked at placing it between the radiator and the front grill, plumbing it through the left side, maybe your oil cooler would fit there?

bushy

hmm not a bad idea bushy ...but i have other plans ....about under tank cooling just at the top of the radiator i have made a mould to construct a ram vent up into the under tank area ,,,,,,,,to get rid of the thigh burns that we tend to suffer out here ....

but thinking about it, the little radiator could mount on the left side like your hole huh (but i really didnt want fuel "out front " just in case )

.....hmmm food for thought mate ....cheers

keep at it bushy ....your doing well !!!

Why don't look at an oil cooler as used on the k1200?

ReneZ wrote:Why don't look at an oil cooler as used on the k1200?

Just wondering if a small after-market oil cooler like this will work?



What I'm not certain about ii if there are special precautions to take with the design to maximize fuel flow and minimize potential leakage problems. The unit above is 1" thick by 5" long and steel construction which seems to be large enough to do the job. I'm thinking that the "U" shaped tube will not be a problem in this application.

verry similar to what i have seen rob ...good find !

The other possible source for mini coolers is the bike breakers yards and pick up one of the small oil coolers being fitted to modern bikes. Seriously looking at the picture I assumed it was a commercial unit it looks so well made, just like a bought one as they say.
Regards,
K-BIKE

After reading about this and taking what charlie had to say i went for a look. Anyone seen These or these aussie go cart fuel COOLERS

look on e-bay, lots but not any to fit where I wanted... but then...



http://www.ebay.com.au/itm/Small-Engine-OIL-COOLER-RADIATOR-Alloy-Chrome-/190590002417?pt=UK_Sporting_Goods_Pocket_Bikes_LE&hash=item2c600ca4f1

regards Bushy

sorry if link does not work look at this,





regards Bushy

seen them on race karts
doesnt help make them go any quicker
looks good and the bloke at the local kart shop making a killing out of them
he uses on on his sons kart and always wins so everyone buys what ever on his kart
money can only make you go so fast the rest is the skill of rider /driver