Exhaust clean up UPDATE. You gotta see this!

lovedavdubs · Posted: Sun Mar 12, 2006 11:59 pm Post subject:

Started a new thread.

http://www.thesamba.com/vw/forum/viewtopic.php?t=161181
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82 Air-cooled Westy (Lola)...My other vehicle is a subway.

Beaker · Posted: Fri Mar 10, 2006 5:37 pm Post subject:

Yep. Can now sleep with both eyes closed.

bljones · Posted: Fri Mar 10, 2006 5:33 pm Post subject:

note the dropcloth on the table.

translation: the wife is home.
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Tomswesty · Posted: Fri Mar 10, 2006 3:42 pm Post subject:

So I don't these will fit a subaru, will they?

r39o · Posted: Fri Mar 10, 2006 2:38 pm Post subject:

That's just too SWEET for that salty NY. Save it for when you do the real rustoration to the van. Then it will never see the salt again. It is just too pretty to be used in that way!

BTW: Lube the hell out of it with anti-sieze when you do assemble it for real.
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lovedavdubs · Posted: Fri Mar 10, 2006 1:14 pm Post subject:

Here it is. The complete exhaust system from heater box to tailpipe ready for installation. Brings a tear to my eye. It will go in Sunday.

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

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82 Air-cooled Westy (Lola)...My other vehicle is a subway.

lovedavdubs · Posted: Wed Mar 01, 2006 3:49 pm Post subject:

danfromsyr · Posted: Wed Mar 01, 2006 1:57 pm Post subject:

heavy is good. no send them out to be powder coated or sumsuch.

as for a LT6cyl used in volvos those were straight six and don't fit length wise..

the 5cyl does squeek in, stays VAG engine management for my own sanity and on the road diagnosis of issues.. I have a nice low miles (80K low for a 5cyl they regularly hit 300K+) and some great insightful chat with a fellow who's already blazed his own path and Mfg'd and installed the same into his syncro westfalia.

I'll keep my old used heaterboxes around in case LDD>

See you in the spring.. East coast campin.
dan

lovedavdubs · Posted: Wed Mar 01, 2006 11:53 am Post subject:

Here they are! I'm the proud new father of two beautiful 19lb. twins. These are heavier than I though they would be.

_________________
82 Air-cooled Westy (Lola)...My other vehicle is a subway.

r39o · Posted: Thu Feb 23, 2006 11:03 am Post subject:

danfromsyr · Posted: Thu Feb 23, 2006 8:38 am Post subject:

lovedavdubs · Posted: Wed Feb 22, 2006 5:10 pm Post subject:

r39o · Posted: Wed Feb 22, 2006 4:13 pm Post subject:

Lovy,

When you come out here to So Cali, they will whack your...for not having EGR. You need ALL the smog stuff hooked up and preferrably working if you hope to have a prayer of getting it past the smog Nazis.
_________________
"Use the SEARCH, Luke" But first visit the Vanagon FAQ!

1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....

Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently)

CF · Samba Member Joined: February 17, 2005 Posts: 802

SlowLane · Posted: Wed Feb 22, 2006 12:42 pm Post subject:

Nice work loveda.

I have to admit to some major shadetree-ing with my heater boxes. They were almost as bad as yours. I made extensive use of JBWeld to seal up the ragged ends of the sheet metal, and one side seam which had started to come apart.

On the flanges, which were eaten away to about half their original thickness, I used a flat bastard file to flatten the mating surface as well as I could, then I sanded out the rust with my Dremel. Then I applied a thin layer of JBWeld to the flange surface and clamped a flat plate to it with a sheet of wax paper between the plate and flange. When the JBWeld cured, I filed it flat again. Repeated until I had something that resembled a real flange.

Yes, I know that it's an ugly hack, but I did it for several reasons:
I figured that I had nothing to lose by trying. I could always order new boxes if I messed up.
I had heard that the new heater boxes were not of the best quality, so original boxes would be the preferred choice.
I had spent quite enough on this rebuild up to this point. Spending another $600 on new heater boxes would have just hurt too much. Sad

After 5 months, the bastardised heater boxes are still sealed up perfectly. No complaints yet.
JBWeld - Better than duct tape. Smile

Fitment tips:
Use the copper nuts on the exhaust studs.
Use the good quality sandwich gaskets on the heater-box-to-crossover connection.
Test assemble everything before you go to install it on the engine.
Install the heater boxes loosely (ie. don't tighten the exhaust manifold nuts) until you have the crossover pipe installed. Fasten the crossover pipe to the heater boxes before snugging down the exhaust manifold nuts. This ensures that the heater box flanges line up with the crossover pipe with the minimum of fuss.

Best of luck.
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Back in the day:
'72 Super Beetle
'69 Camper Van - Corvair powered
'71 Window Van - Transferred Corvair from '69

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lovedavdubs · Posted: Wed Feb 22, 2006 11:54 am Post subject:

Wow! this thread really took off since the last time I checked it. Thanks for all the responses! That is a bolt welded in the EGR tube. It was done by a PO. Doesn't matter to me though. That whole system is long gone on my engine Rolling Eyes

Also a PO modification Rolling Eyes

My old cross over pipe has a gapping exhaust leek at that exact location.

Thanks for the link Dan Wink

and thanks for the vote of confidence ms.

Mulcheese · Posted: Wed Feb 22, 2006 11:26 am Post subject:

I don't want to block it off but I am missing the EGR filter, the valve is stuck closed, ( tried to free it with out success), and the linkage is broke. From what I've read to replace those parts is in the range of hundreds of dollors that I don't have. I would love to keep everything stock but at the moment it is not possible. Maybe some day but for now that is where I'm at.
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82 Westy: Air is cool!

Karl · Posted: Wed Feb 22, 2006 8:18 am Post subject:

Why do you want to block off EGR?

It is designed to lower NoX emissions.

Its benefit is lowering combustion temperature which is a big PLUS on a aircooled heavy Vanagon. Sure, your mileage will suffer but your engine will last longer.

In the late '70s on US cars, we used to disconnect EGR to improve performance and mileage but the engine would ping on acceleration.
Very BAD thing to have happen. Reconnecting the EGR valve stopped it.
EGR is a design feature that works hand-in-hand with all the other emission controls. NoX forms when combustion temps go above 2500 degrees F.

Mulcheese · Posted: Wed Feb 22, 2006 5:01 am Post subject:

So lddubs, is that a bolt welded into the EGR tube. I'm trying to figure out what to do with mine once I get the new exhaust. I blocked off the EGR intake at the air plenum but don't what exhaust gases leaking into the heat.
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82 Westy: Air is cool!

mlf · Posted: Wed Feb 22, 2006 3:29 am Post subject:

jay
try the ratwell site or the type2 site.


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