Where to mount an extra temp sensor

[JamesonRacing]

Have a blue thunder 1-4V intake, planning to run a Quick Fuel throttle body EFI, which requires a coolant temperature sensor to be mounted on the block side of the thermostat.  I also want to run the factory sensor for the idiot lights.  What's cleanest option for mounting the second sensor?

Would it make sense to add a port on the back of the manfold to measure the temp at the blocked off area of the water jacket?

[My427stang]

I drill them and add a second bung right next to the original

Here is a hole I drilled with a step bit, super easy, just push the plug in and weld, you end up with much more thread that way



Finished product, local welded was a bit overzealous with a big bead, first and last time I used him, but it didn't leak

[JamesonRacing]

Thanks for the response!   You used an aluminum weld bung from one of the fitting suppliers?

[BruceS]

Ross, I don't think that weld bead looks bad at all.  Tig welding a small bung on a big hunk of alum is a challenge for starters, and you don't want it cracking, breaking off or leaking.  I used to do lots of Tig welding, and my boss impressed on me not to make "tiny welds" as he called them. Idea being a small bead can equal a weak weld joint that could give you problems down the road. 

Bruce

[country63sedan]

Somebody on the other forum made a spacer to fit between the t-stat housing and manifold. He then tapped it  thru the side and put the sensor in there. No welding required . Later, Travis

[Nightmist66]

Will this be going on the 'vert, David?

[machoneman]

Somebody on the other forum made a spacer to fit between the t-stat housing and manifold. He then tapped it  thru the side and put the sensor in there. No welding required . Later, Travis

Now that's a great idea. A bit of work but it keeps the integrity of the intake and can be swapped onto another intake later.

[My427stang]

Thanks for the response!   You used an aluminum weld bung from one of the fitting suppliers?

I got that one from Summit, but they sell them all over

[My427stang]

Ross, I don't think that weld bead looks bad at all.  Tig welding a small bung on a big hunk of alum is a challenge for starters, and you don't want it cracking, breaking off or leaking.  I used to do lots of Tig welding, and my boss impressed on me not to make "tiny welds" as he called them. Idea being a small bead can equal a weak weld joint that could give you problems down the road. 

Bruce

Well it sure is doing fine, that one has been there for 8 years.  I guess I shouldn't knock the guy because of that alone, but it looked a bit over-done to me.  I don't even notice it nowadays turn the key and go

[427Fastback]

I think it looks fine..I agree with Bruce....no small welds on aluminum.I tig weld aluminum at home all the time and 99% of the time I use 1/8 filler rod..

[My427stang]

That's good to know.  I do have an alum spool gun for my Mig, but never tried it, easier to drop it off and let someone do it with a better welder.  You guys ever try one?

[jayb]

I tried welding aluminum with my MIG welder a few years ago and was very disappointed in the results.  Nowhere near as easy to weld, and didn't appear to be as strong as a TIG weld.  Kind of looked like crap, too, although that may have been the operator 

[Heo]

I have welded quite a lot alu with mig. Both with a
regular "home" mig and purpose built welder
It dont look like a tig weld but not ugly
Problem with a regular welder is feeding
you need push/pull feeding to have a smoth
feed .
On a regular mig
I tie a broomhadle to the feedhose to keep
it straight. The aluwire is so soft so it bends
and cause eratic feed

[My427stang]

I have a Snap-on YA212, it feeds steel wire in the standard way, my spool gun plugs in the front and uses its own dedicated spool right at the gun tip and a second gas feed.

I have never tried it, Snap-on guy gave me a good deal on it, and I need it so infrequently that I never bothered filling the bottle.  I'll have to play with it a little on the Chebby parts

[Heo]

Yes thats what im talking about with a litle practise
it gives ok welds.
In high production situations its much faster than
a tig and gives good enough welds
Like when i welded doorframes to the dryers at a
sawmill for 4 weeks straight 
But like you say if you easier and cheaper to farm it
out the few times you need it