Topic: Repairing a heater box crack and other damage?

[390Pony]

Looking for some advice. I'm restoring my original 67 heater box. It has about a 3 inch long crack along the front edge near the cowl bracket. At it's widest separation it's about 1/8" wide. I was thinking of using some JB Weld or epoxy in the crack and compressing the box with a c clamp to close up the gap while it cures or getting some fiberglass mat and resin, putting some resin in the crack, compressing and then putting some mat on the back side to provide more strength. What do you think guys ?

[Twilight65]

I used the JB epoxy on a small crack on mine. Applied it and clamped it tight. Once sanded it was hard to tell as it is just about the same color.
Dave

[ruppstang]

The JB weld works well and holds much better if you add a thin piece of metal on the inside to bridge over the crack.
Marty

[390Pony]

    thanks for the replies...i cleaned up the crack, used jb weld, compressed with a c clamp for a couple days. I then used a small dremel bit to smooth the excess epoxy on the exterior, rubbed a little black paint into the epoxy..no sign of the repair.

[J_Speegle]

   thanks for the replies...i cleaned up the crack, used jb weld, compressed with a c clamp for a couple days. I then used a small dremel bit to smooth the excess epoxy on the exterior, rubbed a little black paint into the epoxy..no sign of the repair.

Would you consider taking a couple of pictures and post them?

I know they will go a long way in helping others understand what you did.

[Oz390]

Done a few boxes and have used light heat with a propane torch to massage cracks back together.  Get it hot to touch and it will move a bit, but not too much or it melts!  Can make realigning easier with some patience.  I have used wood blocks and clapms to realign some significant "wobbles".

For cracks I have moved to a product called Q-bond.  Black powder and super-glue (I think).  Sets instantly and can be sanded or ground.   For recolor I use VHT vinyl dye, spray it lightly on a rag and wipe on, avoiding paint/ink stamps.

[CharlesTurner]

Looks nice.  Are you re-using the original rivets for the brackets?

[J_Speegle]

Yes  nice job

[Oz390]

I know of no way to re-use rivets.  I drilled them out and then bought as close as I could find to original from Hansen Rivets and pressed new ones back in place.

[CharlesTurner]

They spread in a star pattern, so thought you might have bent the splines back.  Guessing you used an aluminum tubular rivet? 

[Oz390]

Missed this one... I tried bending, but they just crack off.  So I just used tubular rivets, as I did not find star pattern, and figured close enough...

[Bossbill]

Other than the motor (waiting on the electric leads), my heater box has been refurbished, new seals and and new core.

After I redid the clips I needed a way to install them with least effort and damage.
I went to the wood shop and sourced some rubber tipped clamps. This compresses all the new foam and brings the case halves together. I used about six and moved at least two of the clamps near to the clip recess.
I used a thick bladed stubby 'jet' screw driver and inserted it into one of the clip's recesses. Position the clip into the recess at the top half of the case. The screwdriver should be in recess on the bottom of the clip.
While pushing down, lean the screwdriver in so it contacts the clip's edge, toward the 'vaulted' portion of the clip. This spreads the clip out. Usually the clip just falls into place with the combined spread and downward pressure.

I like this method better than using a small rubber hammer as it protects the ridges on the case.
[edit -- add pic]

[gimmea250swb]

I pulled my heater box to install a correct cardboard plenum.  The box has these scratches on it.  What's the best way to repair this?  Should I lightly sand the surface and clear it with a clear finish?  It seems like this is what I should do, but I'd like to confirm before I mess anything up.

Thanks!

[gimmea250swb]

I found a thread that used a dark brown wood repair pen and went that route.  Here’s how it came out.

[CT428CJ]

There's a few different methods suggested in both this thread and the one that I started: http://www.concoursmustang.com/forum/index.php?topic=21601.0

I suggest either the black vinyl dye or some sort of black overspray.