Heat Exchangers WILL (did) go back in..

[brownbus2]

Hi

76 FI with 72-74 exhaust. I took off the exhaust (I cant remember what led to it other than trying to get to that pesky alternator bolt.,,and wanting to clean it up).

Now the HE on the passenger side will not go in. The other may not either but this is as far as Ive got.

When I took it off I did use a rubber mallet to help it off.


Do I need to remove the bolts to reinstall?

Could the bolts be bent?

will removing the pushrod tubes give me much more wiggle room to line everything up?

The alternator adjusting mount is also hindering maneuvering.

I apologize for so many silly questions. I am just frustrated that this whole gas tank replacement has snowballed. I shoulda just replaced the tank and not done all the other stuff...But I wanted to try. And needed the completion of a challenge to help my confidence...TMI I know...

But thanks in advance for any help....
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formerly known as Brown_Bus
1976 FI Marino Yellow Westy

[busdaddy]

Welcome to the world of vintage vehicle ownership, if it was easy everyone would have one.

The heat exchangers warp over time, once removed they spring out (or in) and make reinstallation challenging. There's various ways to straighten them, bars, big pipe wrenches, jacks between the pipes, hammers, etc.... After you get them tweaked so they go over the studs nice and into the recesses for the gaskets you'll have to file or belt sand the ends of the flanges so they are flat and parallel, sounds like big fun eh?

When it's finally time for the last install anneal the copper rings so they seal up nice.
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[orwell84]

You could try grease on the studs, but they are an ass ache to get on and seal properly even on an engine stand. You could also use a round file to open up the holes in the flanges a little to give you more wiggle room. I wouldn’t pull the push rod tubes though. I don’t think it would help much.

[brownbus2]

Just went out and tried to Driver side and it slid right on. So that boosted my mood and lowered my contribution to the swear jar.

Just throwing out ideas here...how often to the studs get bent? Could it be that happened and that isnt allowing the holes to line up?

Ok next question...that HE is starting to split at the pinch seem. Or rather, the pinch seem has come unwelded. will this continue at a quick rate and I will be replacing that HE soon down the road? Just thinking, if so, how much, if any, easier a new HE will be in installing. These are about 12 years old , but, not a lot of miles on them. I had the cerama-chromed when new. They are not as pretty now.

This project has hit so many bumps...should have been easier..
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formerly known as Brown_Bus
1976 FI Marino Yellow Westy

[brownbus2]

As usual, I vent on here, go back out, try again and, Success!

Oh boy....
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formerly known as Brown_Bus
1976 FI Marino Yellow Westy

[cmonSTART]

Invoice is in the mail.
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'78 Bus 2.0FI
de K1IGS

[orwell84]

[ivwshane]

I’m curious as to how well your cerama-chrome held up, any pics?
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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[jlrftype7]

[orwell84]

Me too. Could you send some photos of them in their current stare please?

I am just finishing up mine. They required quite a bit of welding. I won’t be getting them ceramic coated or using VHT. I will be using a rustoleum here gh heat paint on the inside (rated for 1200*) and another product on the outside rated for 500*. I still have the original factory paint on mine and it looks to be nothing special. The insides will be well insulated so I hope that will help. If they don’t hold up, I will have to try something else.

I recently had trouble fitting a used set in good condition. I had to clearance the exhaust ports on one of the heads a little to get it to fit. I did not try to bend the pipes as the sealing surfaces were already flat and parallel. I am running AMC heads which had less clearance than the old 1800 heads I was running. Fit was fine on the stock 1800 heads.

[ivwshane]

I powder coated mine using high temp powder. The tins have held up really well but the actual heat pipe has not done as well.
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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[brownbus2]

[brownbus2]

HE are on the heads...but not tightened. I realized I did not replace the nuts. How bad is it to re-use the nuts. If I replace should I use the copper or brass? Jbugs has both and I need to order something else from them today.
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formerly known as Brown_Bus
1976 FI Marino Yellow Westy

[ivwshane]

[Wildthings]

Adding a second nut to cover any protruding thread will help keep the studs from corroding as quickly.

The one thing I have learned to do is to bevel the mating edges of the heat exhanger flanges slightly before installing the HEs. A sharp edge can cut into the soft aluminium of the heads causing a chip to peel off that can get caught between the flange and the copper gasket resulting in a leak.