A missing exhaust piece

[MountainBeetle]

Hi folks.
There is this segment missing from my exhaust:

I can find various parts but nothing that fits it. Any ideas? It’s a rectangle going to a circle so it’s tricky to find a piece, and hard to fabricate.
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1978 Beetle, 1978 T2 Panel Van

[Wildthings]

[VDubTech]

Definitely a Vanagon heat exchanger with a Bay window fan shroud, you'll either need to change the fan shroud or the heat exchangers to match them up.
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First Trip in the RustyBus:
http://www.thesamba.com/vw/forum/viewtopic.php?t=279077&highlight=

[MountainBeetle]

Thanks guys, that’s really great knowledge. When I got it I found the gap filled with tinfoil then wrapped in a kind of mesh tape. Oddly enough it hadn’t blown through at all.
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1978 Beetle, 1978 T2 Panel Van

[KTPhil]

Ask the crew of Apollo 13 how to fix this.
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Current Fleet:
- '71 Fastback
- '69 Westfalia
Retired:
- '67 Beetle
- '65 Beetle (x2)
- '65 Bus
- '71 Squareback

[MountainBeetle]

[W1K1]

Personally I would get a piece of exhaust tube and make it rectangular on one side to slide into the fan housing, and round on the other and join the two together with a short section of silicone tubing.
Hammer and a vise
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[Wildthings]

[SGKent]

don't run it until it is fixed or you may have both engine and heat exchanger damage. you might be able to do a workaround using some aviation heat ducting that can be clamped on. I think it would get you by for a short while but it won't last. Good to 500F

Something like this and modify some clamps to hold it.

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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[Wildthings]

You might be able to get away with finding a set of 72-74 heat exchangers with really nice shells and swapping the shells over to your present Vanagon style heat exchangers. Others may know better about the fit.

[airschooled]

'79 federal heat exchangers would be my pick, but we'd have to see the current exhaust setup fully to confirm fitment with the downstream pipes.

I also like that they're bolt-on to the '72-'74 muffler, which is available new in good quality. You'll need an adapter kit, (available from German Supply,) but none of the 79-83 components are available new that I know of, besides a generic muffler and tailpipe.

Robbie
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[Mispeld]

What does the other side look like?

I believe I have the same setup in my '77. The PO trimmed the fan shroud on the left to fit the (I'm guessing) vanagon heat exchangers. Both ends of the shroud were sealed off. I was able to fabricate a duct on the right side to connect it but the left side is just not as simple.

So yeah, to correct this, you'd need '79 heat exchangers and possibly a fan shroud IF it was trimmed like mine. Which also means you most likely have the rectangular exhaust ports instead of the more common oval ports which restricts you from using other common heat exchangers... unless... you replace the heads...

Which is why I've simply left mine alone for the last 8 years or so.
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Tom
1977 Westy. 2.0 Fuel Injected.

[MountainBeetle]

Thanks for the inquiries. See below the both sides. Left first:

Then the right side as it had been patched when I got it:

What the right is like after the tape and tinfoil was removed:

As a note, the left side exhaust pipes have subsequently been fixed and have a new exhaust connector block thingy, and the exhaust connector on the right has a new gasket, so looking better than these older pics.
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1978 Beetle, 1978 T2 Panel Van

[dodger tom]

[MountainBeetle]

Generally speaking, there isn’t a simple way around this, is there, it’s just a whole new heater box with the right connector? (this one?: https://www.justkampers.com/vw-t2-bay-window-parts...-1979.html )
Mine is a 2000cc.

Is removing the old heater box a simple or complex affair? I see it appears only connected to the exhaust tubes with 4 screws and the hot air. On a scale of 1-10 what’s the difficulty?
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1978 Beetle, 1978 T2 Panel Van

[Wildthings]

Pull your heater boxes before you order anything, as it's important that they fit your heads. WV made a lot of strange stuff over the years to adapt these engines to various commercial and military uses, while someone may have made custom modifications to the heat exchangers you now have. Your heat exchangers likely have the style of flanges shown in your link, but that is just not 100% guaranteed.

Do you intend to get your heat working?

[MountainBeetle]

[lil-jinx]

removing the heat exchangers could be as simple has just removing a few nut and bolts,it could also be a real nightmare,with broken exhaust studs,and pulled treads,uneven surfaces not sealing on install,
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https://www.thesamba.com/vw/forum/viewtopic.php?t=620186
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1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy sold dec 2024

1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.

[MountainBeetle]

[SGKent]

1979 or later square port
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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin