Heat exchanger fresh air inlet flap box

[Who.Me?]

Anyone ever cut open the fresh air inlet part of the later style heat exchanger?

I'm wondering if it's possible to shave the top down a little to improve fitment in early buses/trucks where the later style clashes with the firewall?

I know some folks remove the HE and install after installing the engine, but that's a pain to do (restricted access, getting it in round tinware etc.), so I'm wondering whether it's possible to reduce the height.

The closest to a cutaway I've found is this, but it's too blurry to see whether the flap extends right to the top of that 'box' at the inlet end.

I've already hammered down the seam, which helps a little. Just wondering if it's possible to gain a little more space?
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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

[Eric&Barb]

Uncrimp the double exit valve on the rear of the head of the heat exchanger. Then you can see what is inside. Maybe you could drop that area just above the pivot for the flapper valves down a 1/4" or so.

Think if you cut a 1/2 to 3/4"wedge out of the forward side of the neck of the heat exchanger you could tilt the top front end forward and downward some to get a lot more clearance.
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[Who.Me?]

[Stocknazi]

If you are successful can you post a pic of the area you are cutting out.
Never thought about bending that seam over for clearance; that's a good idea.
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