Removed SC Heat Exchangers..will 84 & up replacements fit?

[Boxer_Airhead]

Ok, so when I bought my '81Euro SC from the PO it was know that the OEM heat exchangers were rusted and needed replacment. The PO had purchased a good used set from ebay but never replaced them. Now I know why.

I just took off the old exchangers, went to install the replacements and what do I find, they don't fit. This sucks. I suppose I need to double check part numbers next time. Overall the replacements appeared to be a perfect match before I unistalled the old ones.

Here is the part number for the exchangers I am trying to install:
930-211-029-01

Here is my old exchanger part number:
930-211-025-02

So, is there a way to make these fit on my SC? It looks like the flange is thicker so I would need longer exhaust studs. Also a stub of pipe sticks out of each flange about half an inch right where the gasket goes on, but it appears like it could be cut or pulled out flush with the flange. Otherwise everything else looks like a perfect fit.

My last hope is, does anyone need some great condition 84-'89 heat exchangers? Maybe you have good SC exchangers you don't need.

Well at least I was able to install new oil return tubes and heater flapper boxes for heat that I still can't use.

[mb911]

yup grind the tube down that stick above the flange and make it flush with the gasket mating surface.. kinda back yard but a cheap alternative to new stuff

[john walker's workshop]

yep, long studs would do the job. better buy christian's stud drilling tool or it won't be a good time. or find some thin flange 78-79 exchangers. the lip on the later ones can be removed. i use an air hammer and chisel bit to bend them inward to break the weld. it does require a bit more twisting, prying etc, but the rings do come out.

[Boxer_Airhead]

Thanks for the responses, I am glad that this can be done.

One more question for now:
What exhaust stud do I buy to work with the thick flange, will it be M8 X 55MM?

[Boxer_Airhead]

I was successful at grinding down the lip that stuck out of the flange with a Dremel. The exchangers are now ready for installation. But I need to remove 10 studs first. YESSSS! Luckily two unscrewed during removal of the rusted exchangers.

I am looking into getting Christian's stud drilling guide. That seems like the most realistic method for stud removal.

[SP2]

I bought Christian's tool and it worked great. But you might try the Snap-On removal tool. You will need one anyway to install your new head studs. You can order it online from Snap-On. Get the M8 x 1.5mm thread.

[ChrisBennet]

Originally posted by Boxer_Airhead
Thanks for the responses, I am glad that this can be done.

One more question for now:
What exhaust stud do I buy to work with the thick flange, will it be M8 X 55MM?

The expose part of the stud is 30mm. The guy who does my heads (and replaces the studs for me) recommends getting studs from Porsche as opposed to the generally available ones.
Part # is 999.062.239.02

In the picture below, the top stud is a Porsche one.

The middle one is a high quality one from my local metric fastener vendor. Notice the bulge at the unthreaded center.

The bottom one is the wrong size but it's an example of the kind you can get at a hardware store.



-Chris

[vash]

damn, i would pony up the money for the correct parts before trying to remove the studs. that would be the last resort.

[Boxer_Airhead]

Originally posted by SP2
I bought Christian's tool and it worked great. But you might try the Snap-On removal tool. You will need one anyway to install your new head studs. You can order it online from Snap-On. Get the M8 x 1.5mm thread.

What is the Snap-On part number you are talking about? I looked on Snap-On's website and I only see a stud remover for M8 x 1.25 or 1.0
It looks like I only need a (properly sized) Collet and Housing from Snap-On?

Thanks!

[john walker's workshop]

you don't need the snap-on tool to install the studs. just double nut them.

[SP2]

Boxer,

Sorry, you are right.

1.25

I just checked the tool to make sure and it is stamped with that number.