by I had my heater core re-cored a few years ago but the old heater valve leaked and was in bad shape. I found a NOS aftermarket valve, bought it and installed it, one big problem, the valve was defective in that it simply wouldn't let full flow through the core like the original. Couldn't get enough heat when it was cold.
My first plan was to gut the original and put a bronze slug where the valve was. Upon cleaning it up I found the bottom was rotten and I poked through it with a pic while cleaning it up.
Next I devised a plan to make the entire thing out of copper and bronze. I used plumbing fittings and some bronze sheet from work to make the bracket. I brazed the bracket to the plumbing with sil-phos rod and then fluxed and soldered the plumbing together. I got it together and it's working like a charm and hopefully will be a permanent end to my heater woes.
I also replaced the old fan switch with a 3 speed switch, all I could find, b/c my old one was somewhat finicky and intermittent in operation when switching on. I used FOUR SEASONS #35701. It worked well, I had to delete the U spacer that was on the old shaft and drill the knob out to 1/4". Drilling the knob was challenging to say the least, but I got it done and there was still some of the brass insert and the set screw still worked. The end result looks completely stock, the bezel fit perfectly and now I have 3 speeds.
I also installed a plastic wire controlled valve, FOUR SEASONS #74628, on the inlet line. I plan on shortening my old choke cable/knob and installing it in the valve knob hole in the heater box and have push-pull operation. I haven't gotten to that yet.
Unfortunately I didn't take any pictures of the new copper assembly until I got it mounted, but basically I just mimicked the old valves opening and bracket.
Btw, when I pulled the core to do this, that pos aftermarket valve looked worse after a couple years than the fomoco one that had been on there for at least decades.
My first plan was to gut the original and put a bronze slug where the valve was. Upon cleaning it up I found the bottom was rotten and I poked through it with a pic while cleaning it up.
Next I devised a plan to make the entire thing out of copper and bronze. I used plumbing fittings and some bronze sheet from work to make the bracket. I brazed the bracket to the plumbing with sil-phos rod and then fluxed and soldered the plumbing together. I got it together and it's working like a charm and hopefully will be a permanent end to my heater woes.
I also replaced the old fan switch with a 3 speed switch, all I could find, b/c my old one was somewhat finicky and intermittent in operation when switching on. I used FOUR SEASONS #35701. It worked well, I had to delete the U spacer that was on the old shaft and drill the knob out to 1/4". Drilling the knob was challenging to say the least, but I got it done and there was still some of the brass insert and the set screw still worked. The end result looks completely stock, the bezel fit perfectly and now I have 3 speeds.
I also installed a plastic wire controlled valve, FOUR SEASONS #74628, on the inlet line. I plan on shortening my old choke cable/knob and installing it in the valve knob hole in the heater box and have push-pull operation. I haven't gotten to that yet.
Unfortunately I didn't take any pictures of the new copper assembly until I got it mounted, but basically I just mimicked the old valves opening and bracket.
Btw, when I pulled the core to do this, that pos aftermarket valve looked worse after a couple years than the fomoco one that had been on there for at least decades.
