Rocket Man's 02 Denali Build Thread AKA "THE BEAST"

[George B]

Just looking for options. I would not be happy with the crappy design they used either. The fill tee looks simple enough too.

 

[iamdub]

I don’t know, I might try. It’s on an ear of the tank. It’s leaking on the inside of this hole. The problem is if I make it worse and it won’t hold coolant in the system I probably shouldn’t drive the truck.View attachment 247653

First I was thinking you could go at it with a tiny drill bit at a shallow angle to "route" out a slot along the leaking seam, then pack it with epoxy. Now I'm thinking you could use a thin cut-off disc to slice the seam on the whole ear, spread it apart with a screwdriver or wide pry tool, fill the entire ear full of epoxy and clamp it back closed to cure.

 

[Rocket Man]

Looking back I see that now. Must be flat head screws. Is that ear hollow?

Yes flat head Allen head screws and yes the ear must be hollow, there’s a seam that runs right through both mount holes horizontally instead of that part being solid plastic like you would think it would be. Like I said, it’s a shit design. That plastic seems to squish down when I tighten the screw down. Probably why the epoxy i flowed in from inside the tank didn’t fix it.

 

[George B]

Yes flat head Allen head screws and yes the ear must be hollow, there’s a seam that runs right through both mount holes horizontally instead of that part being solid plastic like you would think it would be. Like I said, it’s a shit design. That plastic seems to squish down when I tighten the screw down. Probably why the epoxy i flowed in from inside the tank didn’t fix it.

Thats ******!

 

[Rocket Man]

First I was thinking you could go at it with a tiny drill bit at a shallow angle to "route" out a slot along the leaking seam, then pack it with epoxy. Now I'm thinking you could use a thin cut-off disc to slice the seam on the whole ear, spread it apart with a screwdriver or wide pry tool, fill the entire ear full of epoxy and clamp it back closed to cure.

I actually thought about doing that but was thinking that might open up a can of worms but you might be right, now that someone else thought of it maybe it’s not so crazy after all. I might give it a try, hopefully I don’t mess up the tank worse than it is.

 

[iamdub]

I actually thought about doing that but was thinking that might open up a can of worms but you might be right, now that someone else thought of it maybe it’s not so crazy after all. I might give it a try, hopefully I don’t mess up the tank worse than it is.

After using that JB Weld Plastic Epoxy to repair a few mounting tabs for some rather large headlight assemblies, I'd trust it or anything similar. Having the whole ear filled to keep it from squashing should be a permanent fix. I'm thinking you'd fill one half and let it sit until the epoxy sets up enough to stay in place when inverted, then flip it to fill in the other half as quickly as possible, remove your spreader tool so the two filled halves connect, then lightly clamp and let cure.

 

[Sam Harris]

Thats ******!

X2

 

[pwtr02ss]

After using that JB Weld Plastic Epoxy to repair a few mounting tabs for some rather large headlight assemblies, I'd trust it or anything similar. Having the whole ear filled to keep it from squashing should be a permanent fix. I'm thinking you'd fill one half and let it sit until the epoxy sets up enough to stay in place when inverted, then flip it to fill in the other half as quickly as possible, remove your spreader tool so the two filled halves connect, then lightly clamp and let cure.

That JB plastic weld is awesome.

 

[randeez]

Yeah but are you trying to save me money or cost me money because those options are all over $125....some are waaaaaay over lol.

Let me know if you need anymore help spending money, I'm pretty good at it

 

[Rocket Man]

Let me know if you need anymore help spending money, I'm pretty good at it

Yeah, I thought I was bad until I started watching you. Now I feel better.

 

[randeez]

I clicked on the link George posted and wasted about a a half hour looking at overflow tanks for myself

 

[George B]

Sorry if my link caused anyone trouble. As my wife often tells me "Stop helping, your not helping!"

 

[Rocket Man]

My angry email to Whipple must have had some effect- they just emailed me and asked for the serial number.

 

[Rocket Man]

Just as I expected, cutting the tank turned into a bit of a can of worms. In order to get to the back sides of both mounting holes I had to really split it open. You can see the pink plastic weld I used, where it flowed into the channel that encircles the hole in the corner. Like I said, shit design. I cleaned everything with lacquer thinner, filled everything including both mounting holes completely and clamped the shit out of it. I’ll drill new holes through the JB Weld after it cures. I figure that’s better than trying to keep those holes clear and will be less likely to leak. We will see.

 

[Rocket Man]

The ******** at Whipple emailed me back to say it’s out of warranty (duh, I told them it was) and the $125 is actually a discount, retail is really $175. Which is a bunch of shit since there is no part number and they’re only included with a supercharger bundle unless your original pos tank develops a leak. And even if there is a part number, Whipple is the one setting the price. F them. I’ll spend more money for a nice aluminum tank before I pay them a dime.

 

[Doubeleive]

you can't integrate it into the vehicle cooling system? how much pressure does it hold?

 

[Tonyrodz]

The ******** at Whipple emailed me back to say it’s out of warranty (duh, I told them it was) and the $125 is actually a discount, retail is really $175. Which is a bunch of shit since there is no part number and they’re only included with a supercharger bundle unless your original pos tank develops a leak. And even if there is a part number, Whipple is the one setting the price. F them. I’ll spend more money for a nice aluminum tank before I pay them a dime.

I'm with you Mark. I bet you could have something better fabbed up.

 

[Rocket Man]

you can't integrate it into the vehicle cooling system? how much pressure does it hold?

No, I’m not interested in doing that even if it’s possible. I’m pretty sure it runs way cooler than the engine cooling system. 5-8 psi.

 

[Dantheman1540]

Hell yeah brother! Get them cold IATs with a big tank!


Actually won't really help driving around IATs but should help keep it from getting heat soaked and reduce the time it takes to recover. I've done bigger pump, lines and heat exchanger but the one thing that showed a noticeable difference on logs was the big tank.

 

[adventurenali92]

I like the painted trim on the hatch. Looks really good. Interesting that you color matched the lift handle as well. I never thought of that. Kinda sticks out to me. But I like the uniform color though. When I first got my escalade pillar covers painted the shop painted them pewter instead of silver birch. I didn’t realize until I put them on the truck. They were WAY too dark.... I was like well crap that doesn’t match. So I had to drive back to him and show him and he was like oh yeah I painted them the wrong color... he ended up having to redo them. I’m surprised though... those esky pillar covers have been on my truck 4 years now and the paint still looks really good. Not a single chip. Hopefully when you repaint, it’ll fix the off color on your pillar covers.

 

[Rocket Man]

this is what i was thinking after he showed the "fill T", nix that and get a cheap ice tank thatll mount in that corner if all you need is a fill/bleed point

https://www.amazon.com/Tank-Reservoir-SuperCharger-Water-Intercooler/dp/B00EPYNQAI

There’s no room for a 2.4 gallon tank.