Wards Header Tank - fitting a sensor

[Baldeagle]

I've just fitted a Wards aluminium header tank and very happy with it, however I do want to fit a low coolant sensor to what is essentially an aluminium box. I've looked at loads of s/h ones on ebay but they all look bespoke to the vehicles they came off - any suggestion of a simple generic sensor I could easily fit which would switch on a warning light please?

Bernard

[mallardstag]

I've just fitted a Wards aluminium header tank and very happy with it, however I do want to fit a low coolant sensor to what is essentially an aluminium box. I've looked at loads of s/h ones on ebay but they all look bespoke to the vehicles they came off - any suggestion of a simple generic sensor I could easily fit which would switch on a warning light please?

Bernard

Hi Bernard,

Something like this would be OK http://www.maplin.co.uk/compact-floa...mounting-12167 or this http://www.maplin.co.uk/medium-float-switch-221987

Simon

[V Mad]

Bernard, you need to have a look at possible positions for fitting. On my kit I use a horizontal switch that mounts on a flat surface at one end of the cylindrical tank. I think the wards one is only flat on the top/bottom, in which case you need a vertical entry one. But yu will need to decide at what level you require it to detect, empty/quarter full/half full etc.

[mallardstag]

Here's the Ward tank - looks like you could fit a level switch almost anywhere. As VMad says the side mounting option will give you greater choice over the warning level.

Header Tank 7.jpg

I recently fitted a 'lights on warning buzzer' to my car and this would also make a good low coolant warning device. Just connect the door switch contact to earth through the level sensor, the LIGHTS contact to any green wire in the car (fused ignition controlled supply) and connect the IGN contact to earth (buzzer is designed to operate only when IGN is off).

You can get the buzzer from eBay: http://www.ebay.co.uk/itm/DURITE-LIG...#ht_1551wt_988

[Baldeagle]

I love this forum - thanks for the advice chaps! - now why didn't I think of Maplins? Chris I think the side is vertical enough so I could probably use the horizontal switch Simon suggested, I'll check later. Doesn't sound too difficult a job and would be a reduction in my Stag Paranoia too, now what else can I find to worry about? (dont answer that -I've plenty on my list already ;-)
Bernard

[DJT]

I recently fitted a 'lights on warning buzzer' to my car and this would also make a good low coolant warning device. Just connect the door switch contact to earth through the level sensor, the LIGHTS contact to any green wire in the car (fused ignition controlled supply) and connect the IGN contact to earth (buzzer is designed to operate only when IGN is off).

I'm no auto electrician, but I think this would only work for the later Stags. Up to at least LD30000 the door switch doesn't drop to earth, it is an in-line switch.

Dave

[Baldeagle]

Looking at the spec of the Maplins switches these probably can't withstand the heat or pressure, being max 80c and I think only around 3 bar (looking at the exactly same thing for sale on ebay - much cheaper too). So need a horizontal type switch (no room for a vertical) but something man enough for the job - nothing I can see on ebay so struggling again...
Bernard

[AlanD]

i bought a kit from CBS, on line, it included the sensor all the wiring and a buzzer, i just need to fit mine but i'm involved in the interior at the mo,

oh CBS is car builder soultions

hope this helps

alan

[Baldeagle]

Hi Alan,
Thanks - a very useful supplier by the look of things, perhaps I'm worrying too much as CBS have a very similar float switch rated to 4bar and 110 degrees c, (£12 too - compared to Maplin £19) just worked out that 20psi equates to 1.37BAR so this one will do fine, only downside is I might buy some more goodies while I'm there!
Bernard

[stag-phil]

Hi Bernard

Hopefully someone will come along who has fitted a sensor to a Wards tank to help you out.

My first thought is why do Wards not have one fitted as standard, is it because due to the design of the tank there is no suitable position or is it because due to the size and shape of the tank it is physically not possible to fit it?

Looking at the picture of the Wards tank there appears to an indent at the midpoint on the side therefore the hole would have to be drilled above or below to ensure sufficient sealing. In which case above maybe too high for the sensor and below too low.

I assume to get a perfect seal the tank would have to be also perfectly flat.

I also assume in order to fit the sensor you would have to be able to drop it in through the filler neck and fish it out through the hole you have made for it.

I considered a Wards header tank as well as the diy/scrapyard approach and in the end bought the VMAD kit. Best thing I ever did, simple to fit, the kit contains absolutely everything and it looks good without interfering with access to the spark plugs etc.

Phil

[AlanD]

hi lads, i was put on to these people from another forum member, they have lots of stuff, i bought all the pipework for a header tank, relays buzzers and a cooling fan for the stag, it was the wrong thing to do when they sent me a book lol all in under £160

alan

[mallardstag]

I'm no auto electrician, but I think this would only work for the later Stags. Up to at least LD30000 the door switch doesn't drop to earth, it is an in-line switch.Dave

Dave,

This depends if you have a late model where the door switch connects to GND or an early model (like mine) where it connects to +12V (purple wires). If, like me, your door switch connects to +12V then you need to add an additional relay to 'invert' the door signal as I have done. For the low coolant warning application you can connect up the float switch so that it connects to GND when the coolant is low and the additional relay is not required.

My wiring diagram is shown here (ignore the fog lamp wiring).

wiring.jpg

Simon

[AlanD]

hi Bernard,

the worst thing they did was to put a catalouge in with my order lol, it cost me, so i have now hidden it lol, i bought a cooling fan kit, all sepaerate for about 100 and all the plumbing bits i needed for my header tank, all waiting to be fitted, but i have to refurb the engine bay first, thats the next job on the list, if you call them they have loads of advice and tell you what you need and how to do it

Alan

[Baldeagle]

Hi Phil,

You raise some good points, yes hopefully someone will reply having sorted this challenge already, I've also emailed Wards and we'll see what they suggest too, waiting a response. The sides of the tank are flat though and I intend to put the hole at the rear of the tank, as long as the sensor can be squeazed in through the pressure cap hole and physically fits in the tank then all should be OK. I'll check the tank later before ordering the sensor.

Bernard

[Bob Heritage]

You can buy a switch that only needs access from one side to fit it, no need to go in through the pressure cap.