Optimistic Quarantine Project - Heater Rebuild '75

[JeffM]

In the 'seemed like a good idea at the time' category:   I decided to tackle the non-op heater box in my '75 given that a) I'm in Maine and it gets cold here, b) there are fabulous detailed directions for this complex project here on the FAQ, c) many of the needed parts are still available, and c) the coronavirus lockdown thing.  This project exposed some crappy past work done to try to keep the 

heater working, and required just about every tool in the shop.  I ended up doing soldering, rust removal, painting, plastic repair, wiring, fabrication and of course cleaning and polishing. Fortunately I was able to find a used heater box with intact plastic (critical).  In the end I followed the FAQ instructions pretty closely, with a few adjustments and tweaks (e.g. adapt the fan cover to accommodate a later heater core with the larger inlet/outlets, etc.). 

 

So I finished installing the heater box yesterday, which of course was the hottest day of the year so far in Maine (83+ degrees).  Other than needing to tighten a few clamps it works perfectly.  Used a newer fan motor and the airflow is strong!   So I guess I'm looking forward to some cold weather?  

 

 

Edited May 29, 2020 by JeffM
Typo

[Mike Self]

Nice job--almost too nice to hide up under the dash!

 

How did you manage to set those pop rivets that hold the water valve bracket without cracking or splintering the plastic heater box?  

 

mike

[JeffM]

mike - Good question. I ended up using stainless 3/8" washers on the plastic side for those rivets, as well at the ones to re-attach the flaps, etc.  Decided against rivets for the final assembly of the fan housing to the box, because it was sandwiching a closed cell foam gasket and that looked like a rivet fail.  Went with stainless screws and washers there.  

[Conserv]

Whew! You had me going for a minute, when I thought your first few photos represented the “after” stage!

 

Looks great! 
 

Regards,

 

Steve

 

[Mike A]

Nice work. Yes indeed ...this job was probably the least  LTROI of all that my turd required. …..too many hours for no benefit since I won't be using the car in the winter

[Mike A]

4 hours ago, mike said:

Nice job--almost too nice to hide up under the dash!

 

How did you manage to set those pop rivets that hold the water valve bracket without cracking or splintering the plastic heater box?  

 

mike

a washer on the blind end takes most of the stress as the rivet expands