Heat exchangers fitting

[Trudie]

I've an exhaust fitted without pre - heat pods. The aluminium hoses go straight to the heat exchangers which posers a problem as the two ends are the same diameter- has anyone got any ideas to joins them to prevent the hoses from constantly slipping off and thus drawing fumes into the cab please?

 

[kempy]

Get yourself a pair of fresh air hose connecting pipes and fasten the lower and upper hoses with jubilee clips (item 12)

I also use clips to secure the hose to the fan shroud and heat exchangers, plus don't forget to fit the rubber seals (item 22) to prevent heat from rising into the engine bay.

https://www.customandcommercial.com/vw-engine_parts/engine--and--exhaust_1200cc-1600cc/baywindow_heat_exchanger--and--exhaust_parts/

 

[Happystamps]

The solution that comes to mind is 2 short pieces of tube with an OD to suit the heat exchanger's ID. you could probably bond it in place, or spot weld, plug weld, or bolt it in. then just connect the card/ali to that.

I haven't been out with a vernier to measure exactly, but I imagine something like this would work fine- cut two 2" long sections, stick 'em in the heat exchangers, stick the hoses on the end.

https://www.metals4u.co.uk/stainless-steel/c8/tube/c85/48.3mm-od-x-2.5mm-wall-304-dull-polished/p2515?showvat=true&gclid=EAIaIQobChMI5PnG0YXf1wIVFuEbCh2j3w7dEAQYAiABEgIIrPD_BwE

 

[Trudie]

Cheers for the ideas, I've been using jubilee clips but it's almost impossible to get the ALI /card pipe to fit the outside of the exchangers as the diameter is the same size. I guess I've kind of done the 2nd above idea this weekend in desperation but used a cut down baked bean can - problem of course is that to get the size right it isn't solid and over tightening the jubilee clip just squeezed it. I think the solid pipe is going to be the way to go. Maybe I'll try to get one made with a bump in to stop it slipping inside the exchanger. Alternatively I'll just go back to a stock exhaust and exchangers!! I'm not a defeatist though -any more ideas very welcome!

 

[kempy]

Trudie,

Personally I wouldn't use the card hose underneath as it gets too hot and will soon split and could cause overheating if you're not careful.
It's more expensive but I fitted CSP steel air hose underneath from the exchangers to engine tinware and then used the card hose in the engine bay connected via pipes as described above.

The steel hose took a bit of fiddling but it goes over the exchangers and is held in place with a jubilee clip and will not rip unlike the card material.

http://www.justkampers.com/vw-t2-bay-window-parts/t2-bay-exhaust-parts/heater-tubes-ducting/stainless-steel-air-hose-50mm-vw-beetle-1961-on-vw-t2-split-1961-1967-vw-t2-bay-1600cc-1967-1979.html

 

[Mags]

Trudie,

Personally I wouldn't use the card hose underneath as it gets too hot and will soon split and could cause overheating if you're not careful.
It's more expensive but I fitted CSP steel air hose underneath from the exchangers to engine tinware and then used the card hose in the engine bay connected via pipes as described above.

The steel hose took a bit of fiddling but it goes over the exchangers and is held in place with a jubilee clip and will not rip unlike the card material.

http://www.justkampers.com/vw-t2-bay-window-parts/t2-bay-exhaust-parts/heater-tubes-ducting/stainless-steel-air-hose-50mm-vw-beetle-1961-on-vw-t2-split-1961-1967-vw-t2-bay-1600cc-1967-1979.html

I've done the same, well worth the cost of the steel hose, much neater and longer lasting solution.