[rheavn]

I thought I would make a thread for this subject. As background I got some clear polycarbonate tubing from Amazon. It is the same od & id as the original radiator overflow tank sight tube. The same tube cap fits in the new tubing.

http://www.amazon.com/gp/product/B000OM9...UTF8&psc=1

Tom had mentioned that the overflow tank company owner said that the sight tube required some extra work. When I removed the tube I see what was being referred to. The 1/2" od will not fit into the black vinyl hosing as it is too big. Therefore he tapered down the end to fit.

Using an open flame I heated one end of my tube and shaped it in a vise. I put a drill bit into the tube so I didn't collapse & block off the tube. I used a drill bit that matched his final hole. Mine did not come out as pretty, but it did slip into the black vinyl hosing. I clamped it and it has passed a 4 hr leak test. Now I'll have to see if it passes the operational test when we go out and hold up to the vibration.

Some one may have experience forming this material and have a better way of forming the tubing. If so please provide suggestions.

Now you know the rest of the story and can decide if you want to experiment as I have or buy a ready made set up. If some one wants to try their own experiment I can bring most of the necessary tools to the rally. The only thing I don't have is a portable vise.

I attached some photos.....................