I did a preliminary layout. I think the best place for the
expansion tank and pressure cap based on the test data is on the input
side.  If the pump input  is ten or so psi below
the output and there is a 15 psi cap on the expansion tank that
means the outlet can be 25 to 30 psi into the block.

This is a two pass rad simply because it is easier to plumb.
Twice the restriction and twice the velocity so heat transfer factors
cancel each other out more or less.

BTW as Don Dunbar pointed out it is real important to keep
the pump inlet as low as possible. On the stock engine
with the high mounted pump a three inch drop in water
level will cause rapid catastrophic overheating as the pump will
suck air. I verified this on the test rig.

Paul Lamar

Can we block off the water ports at the top of the engine and create our
own somewhere else lower on the engine? Not feasible without making a
new side housing?

--
Perry Mick

Yes Jim Mederer has used a freeze plug port just behind the air conditioner
bracket on the front cover.

Paul Lamar
 
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