35d: adding crankcase breather oil separator

[ZetaTre]

The original design was not effective enough so, as some may have read on the other board, I actually went ahead and installed a Mann+Hummel ProVent 200 separator.

I now have about 15,000 miles on the setup and I'm extremely pleased with the results. The oil in the intake has completely disappeared and the oil level in the sump has not declined.

I went through a few iteration and testing to ensure that the crankcase would not pressurize under any driving conditions. I have also modified the dipstick tube to make it the return line for the filtered oil and make the system completely closed loop.

I'm now refining the design of the takeoff plate: someone I know was able to scan the profile of the original CCV and machine the plate on CNC machine for a perfect design. I also found an aluminum elbow and I'll have it TIG weld to the plate for a clean and professional design. The plate currently mounted on the car is the proof of concept I made from a 1/4" aluminum plate cut to shape using a jig saw and soldering a copper elbow: it works but it's not pretty and the solder is fragile and I already broke it once while replacing the hose.

Also the hoses I originally used for the long term testing was a duct made of thermoplastic rubber: it turned out that it is either too porous or not resistant to the oil because the one running from the valve cover to the filter (which carries unfiltered fumes) have developed a film of oil on the outside. I went back to the Gates rubber hoses I had originally but have identified some corrugated nylon conduits that I may try if the rubber hoses don't work.

Some of the key takeaways of the project:

REROUTING THE BRAKE BOOSTER LINE

This was necessary to make enough room for the Provent



MAKING THE BRACKET TO SUPPORT THE PROVENT

Now that the brake booster line is out of the way I removed the bracket that was holding it...



and used it as a template to make a bracket that would go in the same location to hold the ProVent 200



See if it fits...



And install the ProVent 200...