I am making a power steering reservoir for my Subaru. The main body of the thing is a piece of 3'' aluminum intercooler piping about 5'' long with two .125'' caps welded to each end. The inlet port to the reservoir (return from my rack) is a -6 line and the outlet (feed for my pump) is a -10. For a cap i am using a cheap breather type oil filler cap from Mr. Gasket. My main concern is, what kind of baffling should I put inside it? I am worried about foaming in the reservoir and was looking for advice on how to prevent it from reaching the outlet line.

I was thinking about making a sort of sump using a piece of 1.5" pipe with the one end welded to the bottom of the reservoir and the other end welded closed. I'd drill 8 or so 0.25'' holes in it to let it fill up. The outlet would remove fluid from this sump at the very bottom.

I was wondering if welding a piece of pipe, for the inlet, into the side of the reservoir tangent to the curved surface, instead of just welding a bung normal to the surface, would help cut down on foaming?

Aside this stuff do you have any other suggestions?

Thanks,
Ryan

 

IMHO,

Cut open a stock one and copy the baffles that are in that..