Mild performance heating system

[TheViking]

Hi! As i became really tired over exhaust smell inside the car when i used the heater, and the poorly heat, i decided to do something with it. So i decided to change my heating boxes to some "new" original ones without internal leak, which is in better shape, and to convert some original pre-heating boxes to the mild performance exhaust. It all would be wrapped in exhaust bandage to help prevent leaks, keep some more heat and protect from rocks and stuff on the road in general. So after had cleaned the heating boxes i started to narrowing the exhaust, because the engine is 2.6mm shorter. I would also weld on some flanges where the heating boxes meets the 4-1 exhaust. After this i started to adapting the right preheating box. This takes a lot of time and it being my first time adapting anything and only being 17 with limited welding knowledge and a abilities it looks ruff, so keep that in mind. As well as the fact that the boxes had really thin metal and poor quality, so i kept burning through.

And rufley finished it looked like this

Then i did the same thing on the other side and got this as a product

Then i wrapped everything up in exhaust bandage. Note the zip ties are only for mounting purposes as i ran out of hose clamps. So i will change them when i get to buy more clamps.

I painted the preheating boxes to protect for rust.

This is for my sp kadron engine with around 65-70 hp. I am currently gathering parts for a 120hp 1776 with dbw and efi, which i will do the same to with 1 5/8" exhaust. And maybe make my own heating boxes. We will see

When i get finished with installing a full flow system i will try the system, and looking forward to try out the heat. Theoretically it should give some more heat, due to the stainless header going through the preheating boxes will give away some more heat. But in practice i do not know.

[74 Thing]

Good job-please post the outcome.

Scat used to make those headers, but no longer. I have some preheaters sitting for years that I have meant to adapt but have not gotten around to it. Please do mine as well :). Did you just use a cutoff wheel to open them up then slide them over your header then weld everything back up?

FYI that exhaust wrap will hold moisture and rust out your exhaust much quicker.

[vwracerdave]

The plastic zip ties are gonna melt and the header will rust badly every where you have it wrapped.
_________________
2017 Street Comp Champion - Thunder Valley Raceway Park - Noble, OK
2010 Sportsman ET Champion - Mid-America Dragway - Arkansas City, KS
1997 Sportsman ET Champion - Thunder Valley Raceway Park - Noble ,OK

[dirtkeeper]

Bailing wire might be a good option instead of clamps.

Loooks good

[TheViking]

[TheViking]

[TheViking]

[TheViking]

It is stqinless steel*

Another question, can i weld the preheating boxes to the header? The reason i didnt do this is because it comes «loose» from the factory. But if there really isn’t a problem welding them in place, then ill weld them onto the header.

[74 Thing]

The exhaust wrap will deteriorate your header quickly. I would take it off and tack your preheaters to the header. There is no need for the exhaust wrap. The preheaters are meant to heat the air as they pass the #2 and #4 pipes prior to entering the heater box. If you are using OEM heater boxes then put out some 40 degrees more heat at the footwells compared to aftermarket Dansk boxes during my testing. They are much heavier when you hold them due to the added fins inside.

If you do decide to keep the exhaust wrap for whatever reason you can get metal zip ties (ebay) or use a hose clamp. I would strongly recommend removing it.

I did a test where I wrapped a heater box in exhaust wrap to see if it would help add more heat and it did not. Dealing with that fiberglass or synthetic wrap is more trouble than it is worth plus add the moisture retention and that is a bad thing unless it is a drag or sunny driving vehicle.

[TheViking]

[TheViking]

Is it okay to weld the preheat joxes to the header?

[57BLITZ]

[TheViking]

[TheViking]

Anyone?

[TheViking]

I listened to your advice and removed the exhaust bandages from the preheating boxes and heating boxes. I did also weld the preheating-boxes to the header to get it air tight.

Didn’t become pretty, but pretty solid it is

[74 Thing]

What were you using for a welder, rod, etc...that heater box metal is super thin!

Get that engine in the car and the heater running!

[TheViking]

[TheViking]

This is the welding machine i used
https://www.premierwelding.com/lincoln-electric-sp...YcQAvD_BwE

Lincoln electric speedtec 200c

[TheViking]

When this engine breaks, i will build a winter engine with efi and use this exhaust. Just because of the heat. Hopefully around 90-100hp. A buddy of mine built a 1679 with same exhaust (without the modifications for heat), used a 34 pict 3 as tb and got 88 hp. So with dual tb i think i can get 90-100hp. Neat little winter engine with good heat:)

[gt1953]

It is looking good for sure lots of work you have going on there for sure. I did consider doing what you did. My alternative was to make these and the result is more direct air flow thru the heater boxes.

_________________
Volkswagen: We tune what we drive.
Numbers Matching VW's are getting harder to find. Source out the most Stock vehicle and keep that way. You will be glad you did.

72 type 1
72 Squareback
({59 Euro bug, 62, 63, 67, 68, 69, 73 type ones 68 & 69 type two, 68 Ghia all sold})