Since Mazda spent hundreds  of man hours developing the air/coolant
separator it behooves us to copy them. The stock Mazda RX8 plastic can
is running with a .9 bar or 13.5 psi pressure cap which is
inadequate for aircraft use. We need something around 25 psi
or above. Continental uses 50 psi which leads to a much heavier can.
This design uses Zero Manufacturing deep drawn aluminum cans welded
together. It is about 8 inches in diameter and about 5 inches
high. Roughly the same size as the Mazda RX8 can.

The tangential input is from the block. The bottom outlet
goes to the rad. The output from the rad goes to the water pump.

http://www.zerocases.com/metal-products/stock-deep-draw.jsp
--  Paul Lamar ...No rotor no motor.

Paul,  maybe I am not on the right Zero Manufacturing page.  All the
deep drawn cans have a maximum wall thickness of .063 and are made of
1100 or a few 3003.  Are these what  your are recommending?  A good
source of 6061 T6  large diameter tubing is from the suppliers to the
amateur  telescope guys.  Jerry

I think .063 is thick enough for 30 psi but it must be tested.
Tubing with flat ends results in stress concentrations at the weld.

Here is what it looks like installed.

Paul Lamar ...No rotor no motor.

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