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DIY: Windshield Washer Reservoir for the Boosted

Most of us that are boosted (and probably some CAI) had to delete our washer bottles and have just been living with it. I've been boosted for a while now

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Old 01-15-2017, 09:48 PM   #1 (permalink)
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Default DIY: Windshield Washer Reservoir for the Boosted

Most of us that are boosted (and probably some CAI) had to delete our washer bottles and have just been living with it.

I've been boosted for a while now and for the most part, I haven't really missed the washer... but from time to time when you really need it, not having it can be annoying. So I made my own... hope this helps someone!

Background:
Conceptually the washer reservoir is a pretty simple thing. It's just a vented container with a hole for the pump, and optionally a level sensor. It can be as simple as grabbing an empty container (water bottles...detergent bottle, etc) and installing the pump into it.

Requirements:
1) Stock location - There is still a good bit of empty space in there and I want to avoid cutting the factory harness to relocate the pump.

2) Keep the level sensor - because.. why not? I'm always trying to keep my car as factory feeling as possible despite all the mods.

3) Be able to fill from the top of the engine compartment.

What you need:
Level sensor https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
Pump https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
1x 3" PVC pipe, about 8.5"
2x 3/4" x 3/4" NPT hose barbs
2x hose clamps
2x 3" test/knockout caps
18" 3/4" ID flexible tubing
Aluminum or Steel for making brackets (mine was 3/4" x 1/8")
1x 1 1/2" PVC Coupler
1x 1 1/2" PVC Plug
1x 1 1/2" PVC 3/4" Reducer Bushing
PVC Cement
Teflon tape
Epoxy

1 1/2" parts are for the filler neck, 3" parts are for the bottle.

Costs: ~$25 for the PVC stuff (can be found at lowes). ~$30 for the new pump and sensor (or just rip out your OE ones). I had the aluminum laying around.

(Note, picture below shows 1 straight hose barb and one right angle barb... What you actually need is 2 straight hose barbs)



Bottle:

Started out by making a bracket to hold the bottle.. it uses a leftover mount for the OEM bottle.
Here is how I make my brackets.. clamp it down and hit it with a hammer.





Test fit a piece of pipe to make sure it doesn't interfere with the bumper:



Unfortunately it hits the DRL. pre-'13 guys might be able to use this large of a bottle.



Had to cut the pipe and bracket a little shorter.



Test fit with the bumper again - all good!



Resulting size of bracket:



And pipe:



Bore a 1" hole in the pipe close to the edge, ensuring it isn't so close it will interfere with the test cap. If you have a 3/4" NPT tap, thread the hole. I didn't so I just wrapped the barb threads with teflon tape and forcibly threaded it in a few turns. I had originally planned to seal around it with epoxy, but to my surprise this turned out to be water tight.
I used a step bit for all the drilling in this DIY.



Cement in one of the test caps on the barbed end. Make sure you thoroughly scuff and clean the PVC mating surfaces before bonding to ensure a watertight seal. After it cures you can fill in some water temporarily to check for leaks in the cap or around the barb.



Mark where you want to attach the pump (scroll down to see how mine finished out) and bore a 13/16" hole.



Bore a 1 1/4" hole in the other test cap and fit the level sensor. Cement it onto the other end of the 3" pipe.







Filler Neck:

I planned to paint my filler neck so I sanded/filed and filled the 1 1/2" parts to remove the molding imperfections and raised lettering.



Use PVC cement to install the reducer bushing into the coupler. Make sure you scuff and clean the PVC mating surfaces well to ensure a good seal. Install one of the hose barbs into the bushing with teflon tape.



Make up a bracket for the filler neck..



The filler neck is going to where the passenger air box used to be using an existing mounting point (scroll to the end to see). Mark up where you want the bracket on the filler neck and epoxy it in place. Drill a vent hole in the plug (which will be the cap).



Couple coats of paint (I went with texture black)



Attach the 3/4" tubing. My tube was naturally bent from being stored on a spool so I oriented that bend to face the direction I wanted the hose to go.



Thread the tubing down to where the bottle will be and mount the filler neck:



Install the pump into the reservoir and zip tie it onto the bracket. Cut the hose from the filler neck to the appropriate length and clamp it onto the barb at the top of the bottle.
Hook up the harness to the pump and sensor. Connect the washer nozzle hose to the pump.



Cap on (just a friction fit).



And filled (you can see the fluid in the hose):



It takes just over a quart if you fill all the way up the hose. You need to fill it slowly to allow air to escape.

Enjoy!!! (Feel free to give me a rep if you use this DIY!)



Tools I used:
Step bit for drilling holes
crescent wrench for threading in barbs
320 grit sand paper for scuffing PVC and paint prep
Hammer
Clamps

Quick reference hole sizes:
Barbs: 1"
Pump 13/16"
Level Sensor: 1 1/4"
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First DIY Gamma V3 TT Install * Jayhovah's Gamma V3 TT Install Pic'Z and Vid'Z * DIY: Washer Reservoir for the Boosted
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You've got a twin turbo sound system, I think you met your audio goals.

Last edited by Jayhovah; 01-15-2017 at 10:11 PM.
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Old 01-15-2017, 10:39 PM   #2 (permalink)
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i still have mine. Why did you have to delete yours? i had to remove the top part. To fix you just cut fill neck and add a small piece of flexable hose and relocate to passenger side fender well. I could of just removed the top part and fill with a long funnel.
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Old 01-15-2017, 10:54 PM   #3 (permalink)
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Quote:
Originally Posted by woo View Post
i still have mine. Why did you have to delete yours? i had to remove the top part. To fix you just cut fill neck and add a small piece of flexable hose and relocate to passenger side fender well. I could of just removed the top part and fill with a long funnel.
Because of this cone filter (Common placement with most TT kits):
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First DIY Gamma V3 TT Install * Jayhovah's Gamma V3 TT Install Pic'Z and Vid'Z * DIY: Washer Reservoir for the Boosted
Quote:
Originally Posted by redondoaveb
You've got a twin turbo sound system, I think you met your audio goals.

Last edited by Jayhovah; 01-16-2017 at 03:13 PM.
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Old 01-24-2017, 09:07 AM   #4 (permalink)
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Smart! I imagine its a bit heavier than the stock unit but at least its there, good job!
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Old 01-24-2017, 10:09 AM   #5 (permalink)
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Nice, thorough DIY
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Old 06-09-2017, 10:26 AM   #6 (permalink)
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Washer fluid level sensor works....

Attached Images
File Type: jpg washfluid.jpg (95.3 KB, 131 views)
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2013 Gun Metallic Sport - Gamma V3 Twin Turbogized
First DIY Gamma V3 TT Install * Jayhovah's Gamma V3 TT Install Pic'Z and Vid'Z * DIY: Washer Reservoir for the Boosted
Quote:
Originally Posted by redondoaveb
You've got a twin turbo sound system, I think you met your audio goals.
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Old 10-04-2017, 09:14 PM   #7 (permalink)
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I bought an Injen intake without a bottle. I’ll probably do something similar to this rather than spend $100 to get the bottle from Injen.
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Old 12-06-2017, 08:23 PM   #8 (permalink)
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bomb *** washer reservoir!
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