S hose fabrication to clear RSR headers/heat exchangers

[Rivet]

So firstly, I am a very happy first time air cooled 911 owner after a lifetime of wanting. I couldn't afford super nice but I was able to get a good driving and presentable project 1978 911SC Targa.

The previous owner installed a Fabspeed full RSR exhaust with heat exchangers shortly before my purchase and the oil tank "S Hose" that goes from the oil tank to the engine cooler has been resting the on the exhaust primary and has almost burned through. I am definitely happy I found it before having a major oil starvation issue.

From my research it is common for heat wrap to be used, along with companies like BB providing a hard line option with their exhaust. It looks like that even with heat wrap the factory full rubber line will still be resting on the exhaust and even with heat wrap that is less than ideal.

I am an experienced motorsports fabricator with racing motorcycles so I am envisioning fabricating my own back purged stainless section to clear the primary properly and utilizing the rubber bends from the factory S hose to couple everything together.

With that being said does anyone know if there is a product out there already that will make my life easier, and if not, could someone share the oil tank spigot diameter and/or the S hose I.D. so I can do some material ordering and fabricating before draining all the oil from the car.

[Peter M]

I thought I could come up with something better than the Frankenstein BBE hard line old return.

Nope!

Suggest you give BBE a call and ask if they will sell you their old line separately
https://www.bbexhaust.com/shop/fpor-1205-porsche-install-kit-for-fpor-0410-fpor-0415/

[-Levi-]

Subd,
I need this solution for my car as well

[Bill Verburg]

Originally Posted by Rivet

So firstly, I am a very happy first time air cooled 911 owner after a lifetime of wanting. I couldn't afford super nice but I was able to get a good driving and presentable project 1978 911SC Targa.

The previous owner installed a Fabspeed full RSR exhaust with heat exchangers shortly before my purchase and the oil tank "S Hose" that goes from the oil tank to the engine cooler has been resting the on the exhaust primary and has almost burned through. I am definitely happy I found it before having a major oil starvation issue.

From my research it is common for heat wrap to be used, along with companies like BB providing a hard line option with their exhaust. It looks like that even with heat wrap the factory full rubber line will still be resting on the exhaust and even with heat wrap that is less than ideal.

I am an experienced motorsports fabricator with racing motorcycles so I am envisioning fabricating my own back purged stainless section to clear the primary properly and utilizing the rubber bends from the factory S hose to couple everything together.

With that being said does anyone know if there is a product out there already that will make my life easier, and if not, could someone share the oil tank spigot diameter and/or the S hose I.D. so I can do some material ordering and fabricating before draining all the oil from the car.

Do you already have the angled connector piece



I use that and some thermal wrap on the S hose itself

[Rivet]

Originally Posted by Bill Verburg

Do you already have the angled connector piece



I use that and some thermal wrap on the S hose itself

Bill,

I do not, that appears to be a stock inlet that has been modified with an angle? Did you alter the length as well as the angle?

Michael

[Rivet]

Originally Posted by Peter M

I thought I could come up with something better than the Frankenstein BBE hard line old return.

Nope!

Suggest you give BBE a call and ask if they will sell you their old line separately
https://www.bbexhaust.com/shop/fpor-1205-porsche-install-kit-for-fpor-0410-fpor-0415/

Thank you, that is an option I will explore this coming week, if it is available separately and isn't a princely sum it will tempt me to not waste billable time I should be billing customers instead of playing with my own junk.

Michael

[Bill Verburg]

Originally Posted by Rivet

Bill,

I do not, that appears to be a stock inlet that has been modified with an angle? Did you alter the length as well as the angle?

Michael

I bought that from Instant G, he modifies the stock ones, I believe that Rothsport may also have them

AFAIK only the angle was changed
I originally had purchased some -20 braided ss hose for that application but never got around to installing it.

[chrisbalich]

Originally Posted by Peter M

I thought I could come up with something better than the Frankenstein BBE hard line old return.

Nope!

Suggest you give BBE a call and ask if they will sell you their old line separately
https://www.bbexhaust.com/shop/fpor-1205-porsche-install-kit-for-fpor-0410-fpor-0415/

Does anyone have a picture of this installed?
I just spent a ton of time trying to make an S-hose do this job and I'm not in love with the result.

[Joe Bob]

So...is there a non rubber replacement for the S hose that can be used with heat exchangers? I had a failure of the that hose about fifteen years ago and I'm ready to do a preventive replacement.

[Peter M]

Originally Posted by chrisbalich

Does anyone have a picture of this installed?
I just spent a ton of time trying to make an S-hose do this job and I'm not in love with the result.

https://imgur.com/4udCSKe

https://imgur.com/wNk7aqX

[chrisbalich]

Originally Posted by Peter M

https://imgur.com/4udCSKe

https://imgur.com/wNk7aqX

Perfect.
Thank you.

[Rivet]

I am unfortunately too busy at my shop to address my issue properly, I did order some mandrel bent stainless tubing sections to do the final.

For now so I could enjoy the new to me car I ended up purchasing an aftermarket version of the original S hose and heat wrapped the merge collector and two primaries the length that the hose runs parallel and then used a DEI Velcro heat sleeve the full length of the S hose using safety wire to make sure it stayed tight up against the hose. Then I preloaded the hose ends by rotating them before clamping to the spigot to give maximum air gap away from the exhaust.

Next time I am due for an oil change it will be during my slower time at the shop near fall and I can properly fabricate a stainless version with some mandrel bends.

[911 SLANT]

I purchased RSR Headers from Brian at M&K and the S hose has plenty of clearance.

[Rivet]

Originally Posted by 911 SLANT

I purchased RSR Headers from Brian at M&K and the S hose has plenty of clearance.

That looks like a beautiful setup!

The fabspeed "RSR" headers are MUCH wider, If I had purchased the exhaust instead of the PO I would have done things differently but after a little bit of rearranging the Fabspeed exhaust system will work great for now. And since it uses v band clamps, I may be tempted to change the muffler arrangement later on and keep the headers.



This is a 3.2 but the header situation is similar on the 3.0.

[eastbay]

I'd trash bin your headers. Anything that compromises the most important hose in the car is not worth anything to me. Hard to believe they could sell that total kluge. YMMV

[911pcars]

I don't see the compromise. It's an extension using a hard tube. Would you rather compromise the exhaust system? The factory already did that.

Better that tube than a rubber hose sitting next to a hot exhaust pipe. In any case, I would install an insulating sleeve around it.

Sherwood

[Bill Verburg]

Originally Posted by 911 SLANT

I purchased RSR Headers from Brian at M&K and the S hose has plenty of clearance.

The trade off for more S hose room is less ground clearance

the wider spacing has additional advantages for hooking up some mufflers, the narrower for others

I use a FlowMaster muffler plumbing was very strait forward w/ the wider spacing

[911 SLANT]

Here's a shot of my ground clearance. I run euro height.