Dean,
LOL....I have seen two grown men cry over trying to install a stock vw
muffler...many years ago...
I never touch the heater boxes except with a carefully placed prybar
to force them to match up with the muffler.
I quit using the donut method years ago cause the pipes(after all these
years) are never the size they used to be....generally waaay too loose and
leaky.
Do the weld on flanges and you will never be sorry. You will still need a
gently used pry bar and punch to hold one set of the holes in the right
place no matter what.
Cheers, dave
On Sun, 19 Apr 2020, D Johnson wrote:
I always start with confidence and enthusiasm. I loosely install the heater
boxes to allow lots of wiggle room. Then the flat gaskets are slipped over the
head bolts and the fiber donut with concave metal washers are pused onto the
heat exchanger. That's when the trouble begins. I don't think I have ever
successfully joined the muffler (or header) to the heat exchanger. Those clamp
halves don't want to hug the muffler, the fiber donut, and the washer
together. Something wants to slip out. Sometimes it works out with no leaks but
it is never pretty, and I put on my first muffler in 1988. Should I be
modifying the clamps to make them fit better or should I weld on flanges and
give up on the old school method? Is there a better version of the old-style
clamps out there?
My 1915cc engine is back in the '71 Super Beetle with Dual IDFs. I need to work
out the fuel system (tank, fuel line, fuel pump). Then more things to take
care of because the car has been sitting for so long, brakes and lights need to
be checked etc.
Hope you all are well, keeping safe and busy.
Dean Johnson
WIlliamson, NY (Rural NY amoungst the apple orchards)
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