Shop AOS TANK 1" UPGRADE
AOS TANK 1" UPGRADE FOR CRANK CASE BREATHER TANKSOur Crank Case Breather Tanks now use a 1" ID hose from the AOS (Air Oil Separator) tank. Prior to the middle of 2008, they used 3/4" hose. This upgrade is only for kits using the 1" hose.
Remove Factory Nipple / Enlarge Hole
The original factory nipple we attach to on the top of the AOS tank is approximately 5/8" OD but the ID is more like 1/2". The actual hole down inside that factory nipple is only about .200" in diameter. We have always advised our customers to enlarge that hole to 1/2" when installing our breather tanks. But now that we are a full 1" on our tanks, we felt it was time to scale up the nipple on the AOS tank itself to a 1" fitting matching the size on the breather tanks.
With the AOS tank removed, you need to cut out the factory nipple. We used a hole saw, which was quick and clean, but you could use a number of methods. You could cut all the way out to the perimeter of the lowered area if you got carried away, and we would still be able to seal and complete the upgrade. But all you need is a hole equal to the size of the ID of the tube on the new adapter to be adequately sized.
The AOS tank is hollow. We recommend you flush it out and make sure you get all of your cuttings or debris out of the tank before moving on.
Install New 1" Fitting
This new Stainless Steel 1" nipple is welded to a Stainless Steel Disc. In this case, we simply attach the disc to the AOS tank with pop rivets. Drill holes through your disc and through your tank and install the rivets. We used a 3/16" pop rivet in this example.
Seal It Up!
Although not pictured, after the disc is riveted to the AOS tank, we used some high temp RTV Silicone from the auto parts store and sealed the disc to the AOS tank around the perimeter of the disc. And we put a dab in the center of each pop rivet.