BK bypass kit/assemble
 

Pic of current common kit Assy

Bypass block on Bracket
 

Bypass is installed at a 45degree clocking using included hardware. Required wrench size ½” washers are to be used next to red anodized block. The Brkt has three different adjustment heights the middle one is the one shown. The bracket has one leg longer than the other it is to be aft. The Regulator block can be used on either side of the bracket as required. The majority of the time it will be on the Passenger side of the bracket. Third Gens using stock heads bolts can use OEM nuts to install bracket. Removing OEM heat shield is recommended as well. All other installs may need to get two longer exhaust bolts to make up for the ¼” 304 stainless plate. In some twin turbo trucks it maybe required to bend the plate for clearance reasons. The plate comes with reliefs that make this possible.
The Ports on the block are numbered. Number 1 faces front and number 2 is aft. Another easy way to ensure correct oreintation is to make sure the plated regulator is facing forward and down.

Bypass with Fittings
 

45* Fittings are oringed, fittings are to be run down to oring and correctly clocked opposite each other. A backing wrench 1 19/64 (Cresent Wrench) is needed when tightening the 1 ½“ locking nuts.

Head Supply Port Fitting Assy.
 

The fitting that goes into the head wrench size is 15/16”. Recommend using teflon thread sealant on npt threads of fitting that goes into head. (This fitting replaces OEM plug that is located between on aft, top, passenger side of head between cylinders 5 & 6.)
Next is the 90* elbow requries a 1” wrench and a 7/8” backing wrench. The JIC 12 adapter requires a 1 1/8” wrench. Pushlock fittings require 1 ¼ wrench.

Return Splice
 

Requires 1 1/16" wrench and teflon thread sealant recommended on npt threads of fitting that goes into splice. Aluminized steel tubing splice comes unpainted. Some twin turbo trucks are welding a ½” npt bung to the water return line. Instead of a hose splice they will receive a adapter fitting and 90* push lock fitting.

Hose Discoloring
 

The color blue and black are smooth and the outside over time has shown discoloration. The red and grey color hose have yet to show discoloration. A few owners are supplying their own stainless lines. To do so requires AN 12fittings and in most cases about 5’ of ¾ in i.d. line.

The color blue is by far the most popular color used.

Nice post Steve, very well thought out.

Jim