Heater Unit Refurbishment

Sounds like a common problem, Graeme.

Trouble is with mine, I am not sure of the attitude of the adjusting plate relative to the hinged arm on the splines. If I don't manage to get hold of an original in good condition, I will need to get it repaired (not sure this is something I can do satisfactorily at home; I will probably need a machine shop to sort this).

Whatever solution, unless it is a good original replacement which will already be lined up correctly, I will need it to be adjustable so when I put the heater box back I can adjust it to the correct attitude.
 
I may have a solution. I have spoken to a local machine shop who may be able to put a hex type fitting on the end (splining is very expensive).

Can anyone on here give me a steer with regards to the correct attitude of the adjuster plate in relation to the hinged rod?Given re-made splines isn't an option, I need to get the attitude of the two components pretty spot on.
 
I took my poorly heater arm to Richard of RRB machining services of Southend. For a modest £10 he has machined the end of the arm to take a long thin but recessed hex bolt, so the adjusting plate can be tightened up. I can't thank Richard enough. I now just need those rubber tubes and I can then complete reassembly!
 
I am pleased to report I have now reinstalled the refurbished unit, adjusted the control arms as per the workshop manual, replaced the coolant and fired the old girl up.

Wow - heat in a P6 and proper control between hot and cold. I am pleasantly surprised. It was a slog but a job well worth doing. :mrgreen:
 
This morning i tried to take apart a spare heater box that i have, in order to refurbish it and convert it to house an evaporator for A/C.
Well, i have removed all the tiny screws, drilled all the pop rivets, grind all the steel rivets, even split a couple of spot welds on the top corners, but i still can't take the bloody thing totally apart. I have reached as far as removing the nearside panel off, together with the flaps, but the rest remains stubborn. It looks as though the rest of the box is spot welded, even if the spots themselves are not visible.
I have seen photos from various members on here that succeded dismantling it completely, and i wonder if the design of the heater box changed at some, regarding the way it was fastened together.
 
wasn't aware new side rubber drain pipes form heater box were available! have to pop into Wins international in next few months see if they are a stock item. mine are just residual now as broken off near the bend . any idea of costs would deb good too. don't think my busking is doing well ..empty coffee e cup again..
 
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