Sealing exhaust connections - 1600 DP

[Who.Me?]

I rebuilt my 1600 DP engine. In the course of the rebuild, I replaced the heat exchangers with a better old pair and replaced the exhaust with a new Jopex unit that fitted around the filter pump that I also fitted.

I started having problems with exhaust leaks after about 70 miles. The leak appeared to be at the connection with the right hand heat exchanger. I could hear it (like a holed muffler) and see the soot staining on the heat exchanger.

I pulled the exhaust, replaced the wire mesh gaskets and refitted, but the leak was worse than before. The gaskets that were in place when I took the original exhaust offwere very hard wire gaskets. The ones in the aftermarket fitting kit were softer and seemed looser.

Pulling and refitting the exhaust is a pain, so to try to avoid doing it again, I've bought a NOS exhaust fitting kit.

Should I also use any exhaust sealant? I don't want to ruin the gaskets (the NOS kit wasn't cheap) but I want it to seal properly this time.
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Andy


Looking for info on my truck's history. Are you from Campbell California or nearby. Do you recognise it? ... http://www.thesamba.com/vw/forum/viewtopic.php?t=636786

[Clara]

I've got in the habit of using a hi temp copper goo at the exhaust gaskets.

Theoretically it wasn't needed when new, but the old heater boxes are not 100 smooth, and the goo helps fill in the pits. Seems like every few years the beetle gets a stinky heater. Then I re-goo the exhaust donuts. Sometimes it needs new donuts, which means splitting the donut to install. Problem solved. I don't have to remove the exhaust.

[b-man]

I’ve been using Walker Acoustiseal. On the slip connections on early heater boxes and the single exhaust damper as well as all the donut connections. It comes apart easily if you heat it with a torch when you need to disassemble your exhaust.

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1956 Dove Blue Panel
1966 Velvet Green Single Cab
1957 L41 Black Oval Window Beetle

[busdaddy]

[EverettB]

I have this stuff saved in my Amazon list:
https://www.amazon.com/dp/B002RVK668/?coliid=I1HCE4L07NRS29

Members must have mentioned it in the past.
I haven't used it myself so I can't personally vouch for it
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[74 Thing]

[Who.Me?]

Thanks all. Seems that the concensus is that goop is good.

Thanks for the product recommendations too.
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Andy


Looking for info on my truck's history. Are you from Campbell California or nearby. Do you recognise it? ... http://www.thesamba.com/vw/forum/viewtopic.php?t=636786

[TDCTDI]

I just weld 1.5” flanges to the muffler & heat exchangers to lose that crappy clamp connection.

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[RWK]

X2, that's what I do to all mine.
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73 Type 181
63 Type 113
63 Type 261- 428 071
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[Stocknazi]

If the doughnut does not fit tightly on the heater box tube they will leak.

I've cut off and replaced a few heater box tube ends. Mount the heater box and muffler so you can use them to help mock up the replacement end; tack the new tube in a few places, then remove it and weld it up properly on the bench.

I found that dual port intake manifold tube to be the perfect outer diameter, but it's too thin. I used another section of old TV antenna mounting pole to increase the overall thickness. Worked perfectly.
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