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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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Posted: Thu Nov 20, 2014 3:45 pm Post subject: |
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Ok,
The unit is reassembled. I used the recommended clips, VW Part #321-819-059, eleven are required.
As I reassembled I tested the flap operation watching for binding. I lubricated the pivot points, all were good except for the Floor Heat Flaps.
The operating cable for these flaps was severely bent at the control levers and had been for quite some time based upon the deep gouges in the lever body from the cable end dragging across the metal.
I don't know why but the outer sides of the heater flap pivots was distorted, as if it was melted?!?
I removed the flaps.... The ONLY flaps that are easily removed! (Depress the lock tab on the retaining tabs at each pivot point)
I used my heat gun and reshaped the plastic back into the general shape it should be.
I now had some severe binding to fix. The flaps were rubbing on the sides and catching on any irregularities.
A washer at one end fixed that one point but others required filing off almost an 1/8" of flap!
The blue tape is where the plastic was Misformed, the Green tape is where I had to file the heat flaps.
All said and done, it now pivots effortlessly!
Now, here the cables are reinstalled. The control unit is adjusted, the cables completely lubricated inside........ SWEET!!!
Now to install it for a test fit, I need to determine the new air flap operation interface and install the cabin air check valve on the 2" black pipe that I added onto the top.
Sadly, one of these heater flap retainers is missing...... It works fine without it but it would be nice to locate one........
Dave _________________ Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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Posted: Sat Nov 22, 2014 2:07 pm Post subject: |
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It's been a busy Saturday but I finally found a bit of Van Time........
Having the Air Box reassembled, I carried it out to the Van and set it in place.
By doing this I Was able to determine the length of the new Fresh Air Flap operating cable.
I am using the cable that the factory supplied to open and close the rear fresh air flap to operate the new fresh air flap..... (Bottom Lever).
I was also able to determine the length of the 2" ABS Cabin Air Recirculation Pipe I installed onto the Air Box.
I brought the unit back to the warm garage......... And RAN OUT OF PROPANE!!!!
Still, it's out of the wind and the garage is 54* so not bad. I do have a small electric space heater pointed at me as well. It cannot warm the garage but it does warm my aging bones!
Anyway, cable and air pipe cut off, the two cables need to be connected........
What to use??!!?........ I've boxes containing 50 years of misc car crap....... Let's take a look............ Nah...... I've got my Dads stuff as well...... I'm thinking 80 years of accumulated crap!.........
Hmmmmmmm........ A cable clamp........ If I replace the screw with an allen set screw on both sides I can use one screw as an anvil and tighten the 2nd against it, squeezing the operating cables tightly but NOT deforming them.....
So, using some Gorilla tape, I Temporarily taped the two cable housings together.
I was then able to determine the cable operating lengths and clamp them firmly together......... BEAUTIFUL!!!!! ..........
I purposely left the rear fresh air flap cable unmolested, I enlarged the hole to get the 90* crook through....... You never know...... Don't go burning bridges behind you!..........
Next was a permanent cable housing clamp. I used the same 90* angle bracket that I used inside to hold the cable housing in place but I cut it in half so I had two flat plates.
Using 10-32 screws and nuts I securely clamped the two cable together.......
Photo shows the cabin air check valve as well. I stepped it down so that I can brace it from vibrating under the dash.........
Before clamp......
After Clamp.........
Now to go test fit this as a complete unit.
I need to reinstall the wiper mechanism and the washer nozzles before I bolt it into place........
Dave _________________ Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert
Last edited by djkeev on Sat Nov 22, 2014 3:08 pm; edited 1 time in total |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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twowings Samba Member
Joined: September 04, 2010 Posts: 23 Location: Tulsa, OK
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Posted: Sat Nov 22, 2014 3:59 pm Post subject: |
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You've got very admirable fab skills! I've enjoyed following this thru to completion...looking forward to the road test results.... |
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dobryan Samba Member
Joined: March 24, 2006 Posts: 16474 Location: Brookeville, MD
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12103 Location: Port Manteau
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Posted: Sat Nov 22, 2014 5:52 pm Post subject: |
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It's not complete until you add a tube sock over the ABS air recirculation tube _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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Forthwithtx Samba Member
Joined: July 14, 2014 Posts: 717 Location: Fort Worth
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Posted: Wed Jun 24, 2015 9:35 pm Post subject: |
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I'm curious as to how this worked out, Dave. Got an update? |
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CurtisS Samba Member
Joined: March 01, 2006 Posts: 128 Location: Kingston, WA USA
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Posted: Thu Jun 25, 2015 6:41 am Post subject: |
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Yes. I love to hear about how all of your worked out.
Cheers! _________________ If "con" is the opposite of "pro", what is the opposite of "progress"? |
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alaskadan Samba Member
Joined: January 09, 2013 Posts: 1849 Location: anchor pt. alaska
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Posted: Wed Aug 26, 2015 1:21 pm Post subject: |
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So whats up? Got a heater box on the bench and looking to do something too. How's it working? |
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Paulbeard Samba Member
Joined: July 10, 2015 Posts: 2604 Location: Seattle
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Posted: Wed Aug 26, 2015 2:27 pm Post subject: |
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djkeev wrote: |
My conclusion on this Heater/Fresh Air system is quite simply that it Sucks!
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Can I get an "amen?"
I need to re-read this as I just had my "ventilation" box out and could have used some of these ideas. I'm just glad I live in a moderate climate…
Moving the levers to the other side of the box would help by shortening the cable runs/reducing the complexity.
Tempted to put a shop vac as a blower on the front grille to see how the system works without having to drive it. Also wondering if I should hunt up a spare heater box to tinker with. _________________ Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs
— dhaavers |
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alaskadan Samba Member
Joined: January 09, 2013 Posts: 1849 Location: anchor pt. alaska
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Posted: Wed Aug 26, 2015 5:14 pm Post subject: |
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So if i make some flaps that i can manually close right at the point where the heater box contacts the body while another flap opens for recirc air would the inner flaps that just hang there be needed anymore? After thinking about it more they are likely needed when the blower is turned on?
Last edited by alaskadan on Wed Aug 26, 2015 6:43 pm; edited 1 time in total |
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Paulbeard Samba Member
Joined: July 10, 2015 Posts: 2604 Location: Seattle
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Posted: Wed Aug 26, 2015 6:03 pm Post subject: My solution: not for everyone |
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Well, the heater control valve I ordered arrived and that was the work of ten minutes to install. Not able to control it from the dash panel as the cable isn't long enough. I ended up cutting it as low as I could in the doghouse since I couldn't see any other way of getting it. Then I couldn't use it anyway.
I tested the new blower fan and I couldn't feel any air to speak off, not for the amount of noise it was making. I put a shop vac in the fresh air opening and turned it on. Nothing coming out of the vents.
So I got under the dash and manipulated the various levers by hand and found that the cables were binding such that the cable ends were working loose from the lever at the dash or at the flap lever. It became apparent that friction fittings fail after a remove and replace cycle or two. The cables were slipping out of the correct location or just not getting the job done. The flaps could be actuated by hand. So I disconnected all of the cables. The heat control was already done. The footwell vents can stay closed. All that remained was the "defrost" lever and whatever the bottom one is supposed to do.
The "defrost" setting I can just leave on full time as all it does is direct air, heated or not, to the windshield. I suspect that it will not work all that anyway as the vents are too far from the windshield for the blower. I guess Germany must never see any frost, based on these design decisions.
My needs are simple: fresh air, heated or left at ambient temperature.
If I can get a spare heater box to experiment with, it might be worth trying to salvage the concept of this. But I'll live with what I have for now. There are other things that offer a bigger payoff that whatever those levers are supposed to do. _________________ Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs
— dhaavers |
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dhaavers Samba Member
Joined: March 19, 2010 Posts: 7733 Location: NE MN (tinyurl.com/dhaaverslocation)
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Posted: Wed Aug 26, 2015 6:38 pm Post subject: |
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^^^ Might your blower be wired backwards...???
I'd describe a properly functioning blower on defrost as "just-shy-of-hurricane" force...
(Apologies to Katrina survivors...) _________________ 86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS> |
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Wildthings Samba Member
Joined: March 13, 2005 Posts: 50257
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Posted: Wed Aug 26, 2015 6:40 pm Post subject: |
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You want the bottom lever moved all the way to the right for maximum airflow out of the other vents. The bottom lever shuttles air to the back vents when in the open (to the left position) and by the time the air reaches there it will be at approximately the temperature of the body shell. Very hot in the summer and very cold in the winter.
The side vents on the dash have their own built in control flaps that don't always work all that well. There is an old thread where I showed my solution for this, the fix has worked well for quite a few years at this point.
Depending on the model year these side dash vents will have either ambient air or heated air. |
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Paulbeard Samba Member
Joined: July 10, 2015 Posts: 2604 Location: Seattle
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Posted: Wed Aug 26, 2015 6:54 pm Post subject: |
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dhaavers wrote: |
^^^ Might your blower be wired backwards...???
I'd describe a properly functioning blower on defrost as "just-shy-of-hurricane" force...
(Apologies to Katrina survivors...) |
The thought had crossed my mind. I can feel air moving now that I have the vents sorted so it seems to be functioning properly. Wiring this one was simply connecting two spade connectors to the plug that was already there. _________________ Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs
— dhaavers |
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Paulbeard Samba Member
Joined: July 10, 2015 Posts: 2604 Location: Seattle
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Posted: Wed Aug 26, 2015 7:19 pm Post subject: |
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djkeev wrote: |
Ok,
The unit is reassembled. I used the recommended clips, VW Part #321-819-059, eleven are required.
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I just drilled through the tabs and ziptied it all together. There were no clips on the original when I pulled it. I did have to cut the box apart where the larger tabs had been melted together with some solvent: they were almost seamless.
djkeev wrote: |
Sadly, one of these heater flap retainers is missing...... It works fine without it but it would be nice to locate one........
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Both of these fell out of the passenger vent on mine today: I just contact-cemented them back in place. Since they won't be under any stress, they should stay in place now. Without both of them, I suspect you'll lose the other one as the control rod gets used. _________________ Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs
— dhaavers |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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Paulbeard Samba Member
Joined: July 10, 2015 Posts: 2604 Location: Seattle
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Posted: Wed Aug 26, 2015 9:39 pm Post subject: |
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djkeev wrote: |
FYI.....
Modified heater box?
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Excellent news…installed already? _________________ Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs
— dhaavers |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32432 Location: Reading Pennsylvania
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