fast warm up ideas: Exhaust heat exchanger

[oil pan 4]

Last 6.4 coolers are up for sale and I have no idea when I will be getting more.
I am going to remake my pressure washers base platform and use a 6.0L cooler as the heat exchanger since the 6.4L coolers sell a lot better in pairs. I am going to attach the 6.0L cooler to the pressure washer with out modifying it, so if it doesnt work I can still sell it.

[oil pan 4]

I have some 6.7L cummins EGR coolers. I like these.
They are bulky, heavy and well made. You could make a boiler or superheater out of one of these.
Unlike the 6.Oh-no ford coolers which are light, flimsy and are known for being an almost guaranteed point of failure.

If I was going to put one of these EGR coolers on a vehicle to be used as a heat exchanger of some sort I would use a ford 6.4 or cummins 6.7L cooler.

I am looking forward to seeing new ford 6.7L EGR coolers.

[oil pan 4]

Ford 6.Oh no.


Ford 6.4L coolers.


Cummins 6.7L


As far as an exhaust heat exchanger goes what more could you ask for?
Stainless steel, has coolant hose barbs on both inlets and out lets (except for the 6.0L on one end), has exhaust flanges on at least one end.

[oil pan 4]

Have more pictures to post but they are too big

[oil pan 4]

EGR coolers are back in season.
I have some 6.0 coolers and an individual ford 6.4 cooler (the one with out the flexable exhaust end).
I am not going to bother trying to sell the individual 6.4 cooler on ebay. I don't think anyone is just going to want just one.
Ecomodders pay actual shipping (for ebay sales I give the UPS man a Maine zip code, take that quote and that's my standard shipping charge).

[oil pan 4]

Here is a picture showing the difference between a plate heat exchanger and a tube in shell.
This is what a OEM ford 6.0 cooler looks like. The original OEM cooler uses the plate style. That is the EGR cooler that is famous for failing.
The upgrade has the 6 tubes.

Problem is you don't use thin plate heat exchangers when you have high differential pressures and/or high differential temperatures between fluids needing to have their heat exchanged.

There is nothing wrong with thin metal plate, when used in the correct applications, they work great for oil and transmission fluid to coolant heat exchangers.

Tube in shell are used in boilers. High delta pressure, high delta temp.

An EGR cooler used in a diesel EGR cooler application sees both high temperature and pressure differentials. A repurposed EGR cooler will see the high temperature differential but on the pressure side there wont be nearly as much.

[oil pan 4]

Basic concept.


Edit: I just noticed I made an error when I made that picture.
The best way to pump coolant through the cooler is something called "counter flow", which is opposite of what I showed.
You want the exhaust and coolant or water flowing against each other.

[oil pan 4]

Problem is the little light to medium duty pickup truck EGR coolers is they just didn't look big enough for anything I would want to use them on, until now.

I found 2 pretty large EGR coolers at the scrap yard today, they weigh about 30 pounds each.



My guess is that they are out off some kind of john deere engine.

[gumby79]

What % open ( will allow air flow) Vs blocked (water jacket) would you say. And what size would you suggest to use for an in line (post IC pre intake)on my 5.9 12v cummins?
Thanks in advance.

[LittleBlackDuck]

Stop wasting time hacking around with crap. Look at the Gen3 Prius or 2010 on Lexus hybrids. They have a purpose built device to do this. It also has a valve for bypass to reduce flow resistance at full throttle.

Google "Lexus exhaust heat recovery"

Simon