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How I augmented my heater flapper boxes
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tootype2crazy
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PostPosted: Tue Oct 22, 2013 7:26 pm    Post subject: How I augmented my heater flapper boxes Reply with quote

I checked my heater flapper boxes or control valves, whatever you want to call them, with the cable taught and the lever fully extended and there was still a good amount of air coming out of the dump side. Buses need all the air pressure and heat they can get so I set about to fix it.

I got some extreme temperature closed cell silicone foam from mcmaster-carr, the non-adhesive kind shown here : http://www.mcmaster.com/#standard-foam-sheets/=p1yf9j

Here it is:
Image may have been reduced in size. Click image to view fullscreen.


I scraped out the old fiber/wire mesh material that was in there (a lot of work). I then drilled holes in the flaps and with small long nose pliers pushed little stainless socket head screws through the back and then added a washer and nut on the foam.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


After installing NO air comes out the dump side when the heat is on, and NO heat comes out the vents when the heat is off. Also the pressure of the air is significantly higher with the heat on which is nice. No more venting the heat to the atmosphere!
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VDubTech
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PostPosted: Tue Oct 22, 2013 7:32 pm    Post subject: Reply with quote

Nice job, I can't imagine what a pain in the ass putting that hardware on was.
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tootype2crazy
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PostPosted: Tue Oct 22, 2013 7:35 pm    Post subject: Reply with quote

VDubTech wrote:
Nice job, I can't imagine what a pain in the ass putting that hardware on was.


It was a pain in the ass for sure, especially on the dump side. At least I have long spindly fingers which helped. Smile
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air-cooled or nothing for me
1978 Sunroof Deluxe Bus (daily driver)
1978 Transporter (mom's, making into a camper)
1970 Single Cab 2.1 turbo/EFI 6 Rib, 78 front beam, vanagon backing plates on rear (project)
2001 GTI VR6 (wife's)
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aerosurfer
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PostPosted: Wed Oct 23, 2013 1:15 am    Post subject: Reply with quote

I just had my flapper boxes off trying to adjust how well they open and seal. This is a great idea. Which of the foam sheet sizes did u order? any worries about them flaking or curling in such a harsh location?

I'm overhauling my heat system components trying to get more pressure
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Boesen
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PostPosted: Wed Oct 23, 2013 3:40 am    Post subject: Reply with quote

Great job.
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nathansnathan
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PostPosted: Wed Oct 23, 2013 5:54 am    Post subject: Reply with quote

I was messing with mine a few weeks ago and noticed one wasn't closing all the way. I grabbed the arm and tweaked it until it bent the pivot back to where it should be inside and now it seals fine, no foam required - that seems like a moisture trap to me. The spring mechanism in there should be able seal the flapper fully without modification.
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tootype2crazy
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PostPosted: Wed Oct 23, 2013 6:04 am    Post subject: Reply with quote

aerosurfer wrote:
I just had my flapper boxes off trying to adjust how well they open and seal. This is a great idea. Which of the foam sheet sizes did u order? any worries about them flaking or curling in such a harsh location?

I'm overhauling my heat system components trying to get more pressure


The exact part number I ordered was 86235K67. I actually had them glued in for few months to test it out and although the glue didn't hold up, the foam was totally unaffected. There is higher temperature foam on that site if it worries you.
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air-cooled or nothing for me
1978 Sunroof Deluxe Bus (daily driver)
1978 Transporter (mom's, making into a camper)
1970 Single Cab 2.1 turbo/EFI 6 Rib, 78 front beam, vanagon backing plates on rear (project)
2001 GTI VR6 (wife's)
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View user's profile Send private message Gallery Classifieds Feedback
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