Custom heater tube fabrication. Started with 2.5" muffler tubing. Wrapped with high temp. insulation material, then foil tape. Cut opening for cabin heat, fabricated extension tube to mate muffler to heater slide openings. Exactly how the factor did it, basically. When I removed the original heater tubes, I very carefully removed the sheet metal that was welded to the opening. I fabricated new and will re-weld like the factory. Original heater slides will go back in place. This was a lot of work but the results are great. No rust and they will last at least another 40 years.
Tubing with hole to match slider outlet.
View into opening before re-welding.
Space between tube and slider opening.
Oval material fabricated to mate opening with heater tubing.
Oval material after fitting to tubing and opening.
Wrapping heater tubes with high temp blanket material.
Wrapped with foil tape.
Clamping method. I will weld this tight so it will never come loose.
