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<div id="divRplyFwdMsg" dir="ltr">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. <span>Fortunately I found a better heater box in all my mess of VW parts collection so I will be swapping it out soon.</span> </div>
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<div id="divRplyFwdMsg" dir="ltr">Dennis Stiefel</div>
<div id="divRplyFwdMsg" dir="ltr">72 Fastback FI MT</div>
<div id="divRplyFwdMsg" dir="ltr">Rainsville AL<br>
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Jim's idea is the only chance at a real fix, Ive tried every "easy" way<br>
and sometimes they hold around town but once your on the highway for 2 hours<br>
they fail. Even that copper RTV will blow out, muffler cement is your only<br>
hope if the pipes are too pitted.<br>
<br>
Yea, those connections suck!<br>
<br>
Keith<br>
<br>
<br>
I understand that this will be difficult. I use thin alum flashing from<br>
Home <br>
Depot or similar, which you can buy in rolls for a few dollars. Cut strips <br>
~1/2-3/4" wide and long enough to wrap around the HE pipe once.<br>
<br>
Remove the muffler clamp and slide the backing ring and sealing ring <br>
forward just enough to be able to wrap the alum around the pipe. You may <br>
need to "stretch" those rings by prying under them with a tiny screwdriver<br>
to <br>
get them to slide forward all the way against the HE airbox.<br>
<br>
Do a test fitting first, then wet everything with water, pack the muffler<br>
cement <br>
in there and slide the alum rearward under the header pipe. You may be <br>
able to get 2 layers of alum in there, in which case you might be able to<br>
use <br>
a double length piece. You can also use some ordinary kitchen alum foil <br>
strips to fill up the last bit of space if there's not enough room for<br>
another <br>
layer of flashing.<br>
<br>
Then apply more muffler cement (muffler putty) onto everything and then <br>
slide the sealing ring and backing ring over everything. Install the clamp<br>
and <br>
tighten while the cement is wet. Then let it dry. Follow the instructions on<br>
the <br>
tube of cement.<br>
<br>
Yes, it's a fiddly job, not one of my favorites, but it can usually be done.<br>
<br>
-- <br>
*******************************<br>
Jim Adney, jadney@vwtype3.org<br>
Madison, Wisconsin, USA<br>
*******************************<br>
<br>
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