Heater box refurbishment
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- sweetaswesty
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Heater box refurbishment
I’m in the middle of refurbishing the heater box on our Westy. I’ve got the foam kit from Brickwerks, a new blower motor and heater matrix.
Just two questions:
1. How do you remove the plastic ventilator flaps tucked away inside the box? These need refoaming just like the various metal flaps that can be removed in an obvious kind of way, but I can’t see how to get these plastic flaps out and also then put them back. Any one know? For obvious reasons I don’t want to try and force them out.
2. The resistor is working properly at the moment. How prone to failure are they? It looks like replacing it with a PWM (which I’ve got) or the Brickwerks alternative resistor kit option is the way to go, but if these things can be expected to keep on going for a good long time yet I’m inclined to keep the old one. Any thoughts?
Anyway thanks for any advice/ideas.
Just two questions:
1. How do you remove the plastic ventilator flaps tucked away inside the box? These need refoaming just like the various metal flaps that can be removed in an obvious kind of way, but I can’t see how to get these plastic flaps out and also then put them back. Any one know? For obvious reasons I don’t want to try and force them out.
2. The resistor is working properly at the moment. How prone to failure are they? It looks like replacing it with a PWM (which I’ve got) or the Brickwerks alternative resistor kit option is the way to go, but if these things can be expected to keep on going for a good long time yet I’m inclined to keep the old one. Any thoughts?
Anyway thanks for any advice/ideas.
1991 Westfalia California Hightop1.9tdi
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Re: Heater box refurbishment
Hi go westy have a you tube video on doing it
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- ZsZ
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Re: Heater box refurbishment
1 as I remeber you gave to pry out a cap the it can be wiggled out.
2. I think the sticking motor that kills those resistors. With a new blower it should be OK for a while.
But I saw some cheap afrermarket ones on aliexpress a few weeks ago.
2. I think the sticking motor that kills those resistors. With a new blower it should be OK for a while.
But I saw some cheap afrermarket ones on aliexpress a few weeks ago.
Zoltan
1986 Multivan ex-Caravelle. Van since 2006, running mTDi 1Z since 2008 with Fiat Croma 1.9 TDid pump 2008-2019, custom pump since 2019
5spd custom box 4.57 diff + 0.74 5th
1986 Multivan ex-Caravelle. Van since 2006, running mTDi 1Z since 2008 with Fiat Croma 1.9 TDid pump 2008-2019, custom pump since 2019
5spd custom box 4.57 diff + 0.74 5th
- sweetaswesty
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Re: Heater box refurbishment
Thanks but unfortunately the Gowesty video shows everything except how to take the two plastic ventilator flaps out. They’re not levered like the metal flaps but just open and close with the pressure of the air moving through them. They’re partially hidden away within the case work of the heater box but they are supposed to be able to come out. The Brickwerks instructions just show them out and not how to get them out
The plastic knobs are holding the metal flaps in and that’s covered in the Gowesty video and I was able to pull them out quite easily.
The plastic knobs are holding the metal flaps in and that’s covered in the Gowesty video and I was able to pull them out quite easily.
1991 Westfalia California Hightop1.9tdi
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Re: Heater box refurbishment
If I remember they are held in with plastic clips that will be a git to get off due to the plastic being brittle.
Oh wait sorry, you have to remove the bottom of the box to get at those flaps. (just re-read your post )
Oh wait sorry, you have to remove the bottom of the box to get at those flaps. (just re-read your post )
1985 LeisureDrive 2.1DJ 5 Speed syncro conversion project.
1979 LT 2.0CH Westy project
1979 LT 2.0CH Westy project
- sweetaswesty
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Re: Heater box refurbishment
Thanks, but I’ve already split the box and they’re in the top part of the box where the fresh air comes in so I think they’re as accessible as possible without actually taking them out. It is the potential brittleness of the plastic that’s stopping me using any force when I don’t really know what I’m doing. If they were cheaper easily obtainable parts I’d be giving them a strong wriggle to see if that unclips them and allows them to just pull out.
I think I might just have to do as much of the job as I can with them still in situ.
1991 Westfalia California Hightop1.9tdi
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Re: Heater box refurbishment
Could you get a picture so we can see what flaps are the ones you're having difficulty with?
Or just list off the number on that breakdown.
Or just list off the number on that breakdown.
1985 LeisureDrive 2.1DJ 5 Speed syncro conversion project.
1979 LT 2.0CH Westy project
1979 LT 2.0CH Westy project
- sweetaswesty
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Re: Heater box refurbishment
Aargh, no I was wrong and you’re absolutely right. Thanks! I replied too quickly. They’re in the lower half of the box and I need to split the bottom part of the case to get at those flaps - which I don’t want to do but is the only way I’m going to be able to refoam the bottom back edge of those pesky flaps.
They’re 7 in the drawing.
And it’s 12 that I’ve got to get off to get access to them is that right?
They’re 7 in the drawing.
And it’s 12 that I’ve got to get off to get access to them is that right?
Last edited by sweetaswesty on 28 Jan 2021, 22:45, edited 1 time in total.
1991 Westfalia California Hightop1.9tdi
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Re: Heater box refurbishment
Yeah you gotta be careful, when I did mine the bottom was bending when I was trying to unclip it. I thought I was going to break it, just take your time and you shouldn't have an issue.
1985 LeisureDrive 2.1DJ 5 Speed syncro conversion project.
1979 LT 2.0CH Westy project
1979 LT 2.0CH Westy project
- sweetaswesty
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Re: Heater box refurbishment
So does it (the bottom of the case 12) unclip rather than have to be split with a screwdriver/ chisel/ dremel whatever like the top part of the box?
1991 Westfalia California Hightop1.9tdi
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Re: Heater box refurbishment
It's clipped in, I wouldn't pry it too much with a screwdriver due to how it clips together you might snap the plastic. I honestly cannot recall how I took the bottom off mine, I just recall it just pushing back together and clicking into place.
1985 LeisureDrive 2.1DJ 5 Speed syncro conversion project.
1979 LT 2.0CH Westy project
1979 LT 2.0CH Westy project
Re: Heater box refurbishment
I did mine recently there are 3 screws if I remember correctly. It's also plastic welded in places that you need to essential cut.. I used a Shap chissel
Last edited by Rascal on 28 Jan 2021, 23:13, edited 1 time in total.
- sweetaswesty
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Re: Heater box refurbishment
Thanks - all really helpful. I’ll make a start on splitting it in the morning.
1991 Westfalia California Hightop1.9tdi
Re: Heater box refurbishment
Good video from go westy
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Re: Heater box refurbishment
The two number 7 flaps do just unclip if you look with a torch and mirror you can see which way to pull, I found it best to clench your buttocks at the same time in the hope of not snapping the pivot pins off, it worked in my case. Good luck
1985 hi-top 2.1MV with DG carb and LPG
1955 trials buggy with 1.9 DG high lift cam and twin dell's (now sold)
1972 1303 beetle
1992 Audi 100 2.8 quattro estate
1967 Vw Madison kit
1955 trials buggy with 1.9 DG high lift cam and twin dell's (now sold)
1972 1303 beetle
1992 Audi 100 2.8 quattro estate
1967 Vw Madison kit