Boxerworks.com

An idea...

At the rear of the crankcase on the left side there is a screw plug. This is the plug for the gallery leading from the oil pump to the oil filter. remove the plug then drill and tap the hole oversize so you can insert a plug. The plug should block the gallery that leads forward to the filter and have a central hole tapped to allow a banjo to be attached.

A little in front of this hole, drill another to intercept the Oil Cooler gallery and tap it to take another banjo bolt.

Use flexible hoses to run to a spin on filter located somewhere convenient..

OEM oil filter cavity and oil cooler remain as is.

As I say, just an idea. Haven't done any work on practicality but it should work...

Rob

Rob Frankham wrote: ↑Sun Nov 04, 2018 5:42 pm An idea...


A little in front of this hole, drill another to intercept the Oil Cooler gallery and tap it to take another banjo bolt.

Rob

Gidday Rob, thanks for your thoughts and good to read you!

What is the oil cooler gallery, or do you mean the oil gallery directly before the filter?

That gallery plug on the side of the engine is right in line with the frame, perhaps 9mm clearance. I assume that's the plug you're referring to and not the plug on the back of the case?

I'm pretty sure I follow you, divert oil out at the gallery plug, and back in at the new tapping, past the blockage?
The plug that blocks the flow needs to be in the left side gallery plug hole? Of course, I could be well off course.

So essentially filtering with a remote filter, prior to oil reaching the bike's filter cavity? No filter required in the bike's cavity? If the remote filter has an internal bypass, it would provide the necessary bypass function for the system. And the thermostat and oil cooler still function normally?

9mm off the frame isn't much room if I need that gallery point.

I still think the thermostat in permanent fully open position can perform the necessary in and out flow to a remote filter. Easier without installing the cooler plumbing.

At worst without doing anything, I'm up for changing the filter and oil every 5,000 k's. I've thoroughly tested the engine for over 3,000 k with the bypass blocked. I just pulled the filter out and replaced it because I had the headers off, and it shows no ill effects.

There are benefits tho, from putting a remote filter on it.

ME 109 wrote: ↑Mon Nov 05, 2018 9:14 am

Rob Frankham wrote: ↑Sun Nov 04, 2018 5:42 pm An idea...


A little in front of this hole, drill another to intercept the Oil Cooler gallery and tap it to take another banjo bolt.

Rob

Gidday Rob, thanks for your thoughts and good to read you!

What is the oil cooler gallery, or do you mean the oil gallery directly before the filter?

Hi,

Sorry about that, my typo... yes I meant the oil filter gallery.

Yes, you have the idea exactly right and, as I say, it is just an idea. Incidentally, the plug at the rear of the engine you refer to is also the same gallery. The one on the side is the end of the drilling going to the oil pump. The one at the rear intercepts this and carries the oil forward to the filter. You could use either in this scheme.

Rob

Taking the oil from the rear plug would be easy enough. blocking the gallery with a plug in the side hole is problematic as it would block feed to the rear hole too. So I think a gallery block is needed 'after' the left gallery plug.
Then the return oil can go back in after the gallery blockage, but before the oil filter canister.
The exterior return line from a remote filter could also be tapped into the end wall of the oil filter cavity. There's a nice flat machined face to work with there, straight into the oil filter cavity.

However I think this method to be too complex of a solution to the problem.

ME 109 wrote: ↑Tue Nov 06, 2018 1:18 am Taking the oil from the rear plug would be easy enough. blocking the gallery with a plug in the side hole is problematic as it would block feed to the rear hole too. So I think a gallery block is needed 'after' the left gallery plug.

I would simply tap the rear hole beyond it's junction with the latiitudinal gallery, the one from the oil pump, and insert a threaded plug to block the longitudinal gallery (to the oil filter)... loctite it in place. Then leave the external plug in the latitudinal gallery. This would give a direct connection from the pump to what would now be a port at the rear of the block. Maybe increase the size of the thread here so that the banjo bolt could have a big enough drilling for full flow.

ME 109 wrote: ↑Tue Nov 06, 2018 1:18 am Then the return oil can go back in after the gallery blockage, but before the oil filter canister.
The exterior return line from a remote filter could also be tapped into the end wall of the oil filter cavity. There's a nice flat machined face to work with there, straight into the oil filter cavity.

Good call, the ideal place to bring the oil back into the system.

ME 109 wrote: ↑Tue Nov 06, 2018 1:18 am However I think this method to be too complex of a solution to the problem.

You're very possibly right but it's good to think out of the box sometimes

Rob

Rob Frankham wrote: ↑Tue Nov 06, 2018 1:46 pm

You're very possibly right but it's good to think out of the box sometimes

Rob

Indeed.

If it had to be done, it could be.
70mm approx to where the plug would block the gallery, just past the lateral plug. Probably best as you say to oversize the rear plug bore all the way to the junction, then tap the exposed gallery for a 1/4" long plug.
I think the gallery might be about 6mm diametre? I've never measured it.

Big job, all up.