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Old 05-28-2014, 06:36 PM   #1 (permalink)
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fast warm up ideas: Exhaust heat exchanger

These EGR coolers are horrible for power and fuel economy on the diesel engines they were originally fitted on. But they have other uses.
These are stainless steel tube in shell vessels purpose built to exchange heat between a vehicles exhaust and its coolant.
How does it get any better than that?

Possible uses for these EGR coolers include:
Coolant warmed air intake heater
As an air to water after cooler for smaller turbo or supercharged gas or diesel engine.
Its intended use (as a coolant cooled EGR cooler) on some other kind of engine.
As a exhaust powered coolant heater for engines big and small.
A steam super heater (do that at your own risk).
And what ever else you imagination can come up with.

I have seen a few posts about using cooled EGR or more EGR and trying to find ways to try and reuse waste exhaust heat. Main problem with these ideas was the lack of cheap easy to get parts built for this kind of job.
Now we have the technology.

The problem with running some kind of exhaust to coolant heat exchanger is when you don't want any more exhaust heat flow to your coolant you cant just shut off the coolant flow. That seems like it would be the easiest way to stop the heat transfer, but would superheat the coolant and that would be very bad for the coolant and the heat exchanger.
So we must shut off the exhaust flow to the heat exchanger. Sounds difficult right? Not really.
This can be accomplished with exhaust cut outs for large heat movement projects or a universal or external turbo waste gate can be used for smaller heat transfer projects. Waste gates go from about 1 inch up to about 2.25 inchs in diameter. Cut outs start around 1.5 to 2 inches and just go up from there.

I found a hord of take off 6.4L ford powerstroke EGR coolers.
If any one wants one real cheap to experiment with on say a gas or different diesel engine, just be a long time member and PM me.
Price will be shipping plus $10 over what I pick them up for, just a finders fee. (I think each one will cost me around $5 to $10)
Other wise I am going to try to sell them on ebay for a lot more.

Edit: The hoard of exhaust coolers is long gone, I had milk crates stuffed with EGR coolers, altogether weighing 100s of pounds. I never though I would be able to sell them all.
I get a few here and there every now and then.


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1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.

Last edited by oil pan 4; 07-01-2015 at 01:58 AM..
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Old 05-28-2014, 08:18 PM   #2 (permalink)
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I was watching truck U on the speed channel and they had one fail dumping coolant into the engine. Solution? EGR delete. The truck ran cooler and had a hell of a lot more power.
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Old 05-29-2014, 03:13 AM   #3 (permalink)
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Quote:
Originally Posted by Cobb View Post
I was watching truck U on the speed channel and they had one fail dumping coolant into the engine. Solution? EGR delete. The truck ran cooler and had a hell of a lot more power.
Thats what happens when you run a ton of drive pressure.
They aren't doing the really hard working diesels any favors at all.
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Old 05-29-2014, 10:09 AM   #4 (permalink)
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Do you have pictures/dimensions?
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Old 05-29-2014, 02:02 PM   #5 (permalink)
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Might be interested in 3 or 4 of them. Let me think about a day or two.
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Old 05-29-2014, 02:10 PM   #6 (permalink)
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Yes and I will put detailed dimensions for them.
And I will pressure check them. I was told these were take offs and I looked at several of them and none appeared to be leaking.
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1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.
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Old 05-29-2014, 04:04 PM   #7 (permalink)
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Ok I have one ford 6.0hNo cooler (appears to be the most difficult to hook coolant up to), 2 styles of 2008 to 2010 ym 6.4l coolers. Then some other ones I have not identified, might be LLY duramax coolers.
Shipping will be up to $30, the closer you are to me the cheaper it will be.
If you want one and are in the lower 48 I should be able to let them go for $50 or less each, if you don't need it modified.
Remember I do stainless steel fabrication, so if you need one modified a little I will do it cheaper than any welding or machine shop.
Most of these have 2 bolt flanges to hook up exhaust, coolant hooks up with anywhwere from 1 inch to half inch hose, There are tons of pictures on ebay, I will start listing dimensions here shortly.
I have to put a few on ebay, people are asking stupid amounts of money for used ones on there.
So not only will I supply ecomodders with cheap exhaust heat exchangers I will modify them so you can actually put them on your car sooner rather than later.
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1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.

Last edited by oil pan 4; 05-29-2014 at 04:10 PM..
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Old 05-29-2014, 08:43 PM   #8 (permalink)
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The 6.4l powerstroke egr cooler is withthe flexable exhaust outlet or inlet 24 inches long.
This one has 3 coolant ports. The smallest one appears to be a bleed port and takes a half inch hose and has a tiny port useless for moving large volumes of coolant. The other 2 coolant ports are 7/8 inch and 5/8 inch. The 5/8 and half inch bleed port are next to each other.
The exhaust inlet and out let ports are both 1.5 inch. Flange bolt holes are centered 2.75 inches apart.
There appears to be a sensor port, which I verified to be 1/4NPT.

Possible modifications:
The half inch bleed port might be drilled out to something useable or welded over and plugged up.
The flexable outlet can be bent in any direction needed.
The 1/4"NPT port could be used to direct more EGR back to the engine.
The non flex outlet 6.4l cooler should be about 4 inches shorter and that will make shipping little cheaper.
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1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.
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Old 05-31-2014, 11:13 PM   #9 (permalink)
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The horizontal 6.4L EGR cooler is about 20 inches long, about 4 inches shorter than the other one.
No flexible exhaust end, no coolant bleed.
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1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.
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Old 06-02-2014, 06:10 PM   #10 (permalink)
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Bug - '01 VW Beetle GLSturbo
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Since I dont have a car to put one of these on, yet.
I was thinking a test is still in order.
Attach an EGR cooler to my 212cc 7hp pressure washers exhaust. Pass a known amout of water through the heat exchanger, measure the delta temperature.
If it works well I may have to attach one to my pressure washer and enjoy having the pressure washers water warmed for free.
I figure a 7hp pressure washer running flat out has to be burning roughly the same amout of fuel and generating about as much exhaust as an aerodynamic ecomodder car being driven for fuel economy.
How does that sound?

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1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.
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