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I had a very similar problem in my 911SC. But the blue smoke wasn't polite enough to stop after a few minutes. So I discussed it with Mark Cummings at AutoSport in Stowe, MA and he said some of his customers had found relief using "drip shields" to keep oil off the heat exchangers. He said the exchangers were crimped rather than welded, so there was no way to keep oil from getting in...unless you kept it off in the first place. True, the best answer is to fix all of your oil leaks...but if your car is a restoration project like mine, then this will require a rebuild. In any event, Mark was kind enough to give me an old heat exchanger as a model so I could fabricate a drip shield of my own. And so far, it has worked much better than I ever expected. It stands as one of my very rare DIY success stories. I went from a choking blue haze to clean, fresh air. Big, dramatic difference.
Soooo...if you are interested, I can email you some pics of my template and of the installed drip shields on the car. But I suspect your "early" heat exchangers will be different from my SC versions. I made two drip shields so I experimented and used different materials. The passenger side shield is just aluminum sheeting bought at AutoZone for $5 while the driver side is a special heat-shielding fabric bought at Summit for $80. Both seem to work equally well.
Also, since you live in Mass and I live in Worcester, you are welcome to come and see the drip shields in person if that would help.
Okay, if there is anything else I can do to help, let me know. I have a lot of empathy for your problem...
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Owner of a wrecked 944
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