DIY Switchable Stage 1-2 BSH PCV Fix

[Cadbury]

Many of you may have seen my DIY that converts a stage 1 PCV fix into a stage 2, if you haven’t here is the link: http://www.golfmkv.com/forums/showthread.php?t=83761

Over the winter it froze and I had to go back to the stock setup.

This year I upgraded the hoses and fittings to a 1/2” ID and added some hardware so it can be easily switched from stage 1 to 2.

Here is a picture of the modified catch can. I won’t go in to detail of how I upgraded all the hardware:

Tools needed:
1/4” NPT tap
1 x 1/4” NPT plug
2 x 3/8” NPT plugs
7/16" drill bit

Here is what the plugs look like

Drill and tap the ¼” NPT hole between the 2 main holes. It needs to be offset slightly to the left so the gasket on the valve cover lands in the middle of the plug. In my case because I had filled in the channel with JB weld so I had to re-create the channel, more on this later

Outside

Inside

In stage 1 mode the 3 plugs are out half way:

Outside

Inside:

Above we can see the channel partially redrilled

In stage 2 mode the middle plug is in all the way and the barb connectors are added:

Outside

Inside:

There would also be a third mode not shown here where the left and middle plugs are in all the way and the right barb is attached. This would create a race can configuration.

Lastly I apologize for the poor picture quality and not having a picture of the final product after the channel was completely re-drilled, but I imagine you get the idea.


-Cad

 

[Akatsuki...]

very nice diy.

I wish BSH kept w/ their 2 piece design, so it would be easy for people like us up in the great white north to revert to plate only.

I have a stg 1 plate i keep in the car incase i get emergencies like such, but i am very fortunate as i don'thave any freezing issues, and i drain my catch can religiously in the winter

 

[Cadbury]

Mine actually froze just behind the plate inside the square outlet on the valve cover.

When I took the plate off the morning after I had it towed there was a chunk of ice attached to it plugging the brass fitting.


-Cad

 

[Akatsuki...]

^forgot to drain it? =p

 

[Cadbury]

The can was drained at the time it froze. I was confused at first when I took the line off of the barbed fitting and was able to blow through the catch can.

It froze in the blue circle above.

When I pulled the guidance block off, there was a square ice cube attached to it.

It probably froze where it did because the size of the hole in the elbow was only 1/4 inch. They have been upgraded to 1/2 inch this year

-Cad

 

[Akatsuki...]

^ cadbury, are you talking about the elbow as in the brass elbow you used?

I know forge has smaller sized inlets on their plate and catch cans, as they claim it helps catch stuff better, but I think having a large one will be just as good, and also having a longer hose. My BSH Stg2+ stood up fine all winter.

 

[Cadbury]

Yes, the brass elbow. The ice was blocking the outlet elbow.

I originally used smaller hoses and elbows so I had a higher velocity through the hose. But it didn't work out to well for me anyways.

-Cad