Puke Tank/ Crankcase Vent / Catchcan Systems.

[bobkatkat]

Oil in the intake of boosted vehicles is a huge problem and the more you modify and add boost the more you exaggerate the problem. After a lot of catch can designs, installs and research on crankcase vent systems and taking ideas from systems that seem to work from the auto and aircraft world, here is a system that I think ( hope) will finally be a solution.

It is a vortex based air oil separator with a remote reservoir. The system maintains a min of 1 inch tubing throughout. All aluminum construction. Has a dip stick opening that also doubles as flush ports for flushing between oil changes.

This is the first of the crankcase vent systems that will be building, and is installed on the tuned Jeep Grand Cherokee Diesel, which shares its 3L CRD with a lot of Mercedes diesels. For those of you that have this engine and its variants, you know the expensive repairs that result from oil entering the intake. Hopefully this is now fixed.

I will be working on a full CC vent system for the B5 S4 with a twin vortex separator and all hard piping, and a more universal system for 4/5 cylinder boosted motors ( god they are easier to work on). I know a lot of you out there have been having the same issues so i will keep the community informed.

[MechEngg]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

This is what mine looks like, prefabricated silicone hoses to a 034 catch can (same centrifugal style vented to atm). Love the look and the fact that it prevents **** from going back into my turbo, intercooler and engine

[bobkatkat]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

Venting to atmosphere is great when you can get away with it and don't mind killing birds (just kidding. see also Crankcase-V1), but some setups require recirculation because air is metered in the system, the 3L crd is one of them.

[Smarty39]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

Been looking for a 'proper' system FOR EVER! You make this and I'll buy...please keep us informed of progress and when it may be available. Good work!

[MechEngg]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

Yeah mine has the option to recirc back to the inlet of the system via another silicone hose but i chose not to do that for right now. Are you going with a prefab'd catch can or going to source a cheap one to include?

[bobkatkat]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

No I am building everything myself. That way I can use a variety of "know to work" features and put them all into one. I have gone the route of modifying manufactured catch cans with good but not great results. I am currently aluminum brazing everything now but if others wanted a system i would probably have some banged out someplace. Brazing great for prototypes or one/offs but way to time consuming.

I was considering a vent to atmosphere, like your system, on a pressure release valve for those times when something fails in the system through a blockage. I think that is a must on some high boost single head applications. I am hoping that the reservoir will stop most blockages along with being able to empty and flush the system easily at oil changes. Realistically if you have more than 5 oz (res capacity) between oil changes then you have a major problem someplace else.

[bobkatkat]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

Been looking for a 'proper' system FOR EVER! You make this and I'll buy...please keep us informed of progress and when it may be available. Good work!

I think I have come up with a design that will work for the S4 I will keep you informed.

I got side tracked when I started to cut and bend the piping for that. Made a tilt/pan head lightweight Jib/crane instead that day ( so many ideas when you stare at a pile of aluminum tube and plate) but that is another post.

[bobkatkat]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

After the first oil change interval on the Merc diesel powered Jeep and 2 oz of oil trapped the design seems to be working very well. Outlet back into the intake is dry.

The second system on the ACR seems to be functioning equally as well.




So I finally got around to tacking together the version for the B5 S4. Just waiting for the Silicone hose to arrive. Here are some visual details.

This is the design that replaces the spider hose and adds in the twin vortex air/oil Separator



The idea is that the two inlets spin the vapor around physically separating the air and oil then the air returns up the center core and hits a second level or separation. Oil/water is then collected in a remote reservoir.

Core


Here are the completed Distribution Manifold and the Air oil separator. This is installed on the fire wall is designed to clear all the hard piping/harnesses on the back of the engine.

[Ur0Drivr]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

That is awesome Bob!!! Let me know when you have this ready to go!

[R_Ethug]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

i'd love to put one in my s4

[MechEngg]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

The remote reservoir is a killer idea, this will prevent the oil fumes from escaping like in a typical catchcan assembly. This way the crankcase air won't have a chance to sweep over the collected oil and carry the fumes out into the atmosphere. (this is if you are venting it to atm which is entirely possible with this setup)

[Smarty39]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

Great work and please let us know when it's ready to go...I'd even be the test mule if you'd like

[bobkatkat]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

The remote reservoir is a killer idea, this will prevent the oil fumes from escaping like in a typical catchcan assembly. This way the crankcase air won't have a chance to sweep over the collected oil and carry the fumes out into the atmosphere. (this is if you are venting it to atm which is entirely possible with this setup)

As you stated the remote reservoir keeps the already separated oil away from the incoming vapor, also by clearing out the water and oil the twin vortex efficiency is not affected by a changing volume which is maintained at about a litre. Issues arise with catchcans fill up and block. An added bonus is that you can drain the the reservoir when you do oil changes without having to remove anything. With the position on the firewall there will be sufficient heat to keep the main separation chamber and secondary core clear of oil/water when the temperature drops.

I will be running this recirculating into the intake but it would be possible to vent to atmosphere for track days. The only advantage would possibly be not putting hot low O2 back in the intake but big intercoolers and Meth take care of that.

Rod, Ryan and Kyle,

About 1 metre of the 1" ID smooth wall wire reinforced silicon hose is needed for the S4 and there is only one suppler is in Europe so on top of being expensive stuff the shipping is ludicrous. I wounder how many people would be interested? Chime in.

[R-Audi]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

If you want to copy a race developed system, check out the 2Bennet system... issues is the cost buying from them!

[bobkatkat]

Re: Puke Tank/ Crankcase Vent / Catchcan Systems.

I have looked at the 2bennet system and they also use 1" hard tubing and a vortex system. I have done a similar version but want to reserve the battery area for a surge tank and keep the air oil separator on the hot side of the firewall. The one larger chamber turned on its side has the problem of the inlet is in the same orientation as the outlet. This interrupts the centrifugal process for separation. You would have to have the outlet facing backwards and route the piping back to the front. I really don't like the idea of cutting two 1.25 inch holes in my firewall. The bennet2 system uses the same principles as i am using, that come from aircraft, in that there are two chambers that spin the vapor. My system has two inlets so two vortexes, the transitions are smoother on my design to eliminate turbulence in the piping. As stated my design removes the separates to a reservoir taking it out of the equation. My total tubing length is shorter to help in colder weather.

I think the bennet2 is the best solution out there right now but there is room for improvement, plus $900 plus shipping!!