[T3] I've got another question , same one I asked a while back.

[Dennis Stiefel]

________________________________
I had a heater box where was pitted bad like that and would not seal.  I cleaned the end up and tack weld all the big pitted spots with a MIG welder. Then took a grinder and smoothed it out. I still had to use a little muffler cement because I couldn't get it back perfectly round agin but not near as much as I would of if I had not used the welder first. If you could get it on a lathe of some sort after welding it then that would get it close to where it should be as far as the roundness.  Fortunately I found a better heater box in all my mess of VW parts collection so I will be swapping it out soon.

Dennis Stiefel
72 Fastback FI MT
Rainsville AL


Jim's idea is the only chance at a real fix, Ive tried every "easy" way
and sometimes they hold around town but once your on the highway for 2 hours
they fail.  Even that copper RTV will blow out, muffler cement is your only
hope if the pipes are too pitted.

Yea, those connections suck!

Keith


I understand that this will be  difficult. I use thin alum flashing from
Home
Depot or similar, which you can buy in rolls for a few dollars. Cut strips
~1/2-3/4" wide and long enough to wrap around the HE pipe once.

Remove the muffler clamp and slide the backing ring and sealing ring
forward just enough to be able to wrap the alum around the pipe. You may
need to "stretch" those rings by prying under them with a tiny screwdriver
to
get them to slide forward all the way against the HE airbox.

Do a test fitting first, then wet everything with water, pack the muffler
cement
in there and slide the alum rearward under the header pipe. You may be
able to get 2 layers of alum in there, in which case you might be able to
use
a double length piece. You can also use some ordinary kitchen alum foil
strips to fill up the last bit of space if there's not enough room for
another
layer of flashing.

Then apply more muffler cement (muffler putty) onto everything and then
slide the sealing ring and backing ring over everything. Install the clamp
and
tighten while the cement is wet. Then let it dry. Follow the instructions on
the
tube of cement.

Yes, it's a fiddly job, not one of my favorites, but it can usually be done.

--
*******************************
Jim Adney, jadney at vwtype3.org
Madison, Wisconsin, USA
*******************************


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