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> flapper box heater attachment - RESOLVED!, with help from this board - many thanks!!!!
tadink
post Jan 5 2013, 04:03 PM
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hi guys -

I'm under the car trying to hook up my heater system - but the wire cable connector from the heater lever in the cabin to the flapper box under the car has me flumuxted! How do you connect the wire heater pull cable to the flapper box? anyone have a picture and maybe I can "McGiver" something together....

thx

td
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rhodyguy
post Jan 5 2013, 04:10 PM
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you need a barrel nut on each of the control valve arms to secure the wire.
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tadink
post Jan 5 2013, 04:16 PM
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QUOTE(rhodyguy @ Jan 5 2013, 02:10 PM) *

you need a barrel nut on each of the control valve arms to secure the wire.


thanks for the reply - I think I know what you are talking about - but it seems the cable is too short and the flapper will be fixed open -

here's the thing I'm talking about - pic


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rhodyguy
post Jan 5 2013, 04:18 PM
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is the heat control handle pushed down?
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tadink
post Jan 5 2013, 04:22 PM
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QUOTE(rhodyguy @ Jan 5 2013, 02:18 PM) *

is the heat control handle pushed down?



Lever is fully down - and the psngr side is certainly too short - I can pull on the flapper box lever and get the thing inside the bracket, but I 'assume' that when I pull on the control handle it retracts the wires - yes?

thx

td
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JawjaPorsche
post Jan 5 2013, 04:24 PM
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Did you put in a new cable? The passenger side is longer that the driver's side.
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tadink
post Jan 5 2013, 04:29 PM
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hmmmm, interesting question - The cable does not look new. I got the car with no heater system hooked up - the cable ends were twisted up around stuff to keep them from being loose.....I don't have them mixed up side to side - I suppose they could be reversed in the tunnel. (IMG:style_emoticons/default/confused24.gif)

how big of a deal is to chase that down?

td
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rhodyguy
post Jan 5 2013, 04:30 PM
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no pict of the rest of the ducting. do the warm air elbows, the tubes the valves mount on, bend towards the center line of the car when they are installed on the heat exchangers?
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tadink
post Jan 5 2013, 04:31 PM
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OK _ I'm going to head out and fuch around with the driver side now - back in a bit. Ideas welcomed! thanks for the help so far - I'll report on the length of the drivers side after I get it lined up.....td
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tadink
post Jan 5 2013, 04:34 PM
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QUOTE(rhodyguy @ Jan 5 2013, 02:30 PM) *

no pict of the rest of the ducting. do the warm air elbows, the tubes the valves mount on, bend towards the center line of the car when they are installed on the heat exchangers?



yes, elbow bends towards the middle and the hat on the flapper box is facing the middle as well....td
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mepstein
post Jan 5 2013, 04:39 PM
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I would buy a new cable and get some barrel nuts. I did that about a week ago and as long as you get the cable length right, it all works fine. Passenger side cable should measure 2" longer than driver side when it's out of the car. I already had a new cable and didn't want to wait for mail order barrel nuts so autozone had some that just needed to get drilled out in the brass barrel to fit the end of the cable. Took 2 minutes to drill and 15 minutes to hook it all up.
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rhodyguy
post Jan 5 2013, 04:41 PM
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with the elbow and valve (arm on the bottom) in place, how much too short is the wire? 1", 2",...
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tadink
post Jan 5 2013, 05:01 PM
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HI guys -

OK< have the drivers side hooked up as well - and both sides are about 2" short.

the reference pic I'm using has the arms on the top -

so, does the barrel of the wire - fat part - fit into the connector on the lever of the flapper box? held in place by a barrel nut?

here is a pic of mine installed, the crappy looking one. the ohter photo is a reference car that was on the hoist at mcMark's the other day so I grabbed a pic so I would know what I was shooting for. I 'think' I have mine in correctly.....

but the wires are about an inch short on both sides....

story of my life, always an inch short! ratz

sigh.

td


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rhodyguy
post Jan 5 2013, 05:27 PM
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arms to the bottom. haynes, p.15 fig.3.4. try switching them side to side.

k
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tadink
post Jan 5 2013, 06:51 PM
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Now I'm not one to doubt Haynes - - - uh, but, wouldn't that move the problem further away not closer?

I've done a bit more poking around and while on my back, rain water running beneath me, under the car, etc etc etc - I've determined that the wires JUST BARELY TOUCH the brackets on the flappers....

sooooooo - maybe with a really long barrel on the nut, it might just work?

I'd love a pic of one that is installed correctly - but I hate to ask any of you to get into the position that you could take one! LOL Having spent the majority of the day under there - oh my. Maybe someone has a scissor lift and could just saunter out there and show me the way the Germermans want it done?

thanks all for helping....

cheers!

td
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reharvey
post Jan 5 2013, 06:53 PM
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The arms on all of my cars are on the top. Is this wrong? They're all hooked up and working.
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JawjaPorsche
post Jan 5 2013, 07:43 PM
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QUOTE(reharvey @ Jan 5 2013, 07:53 PM) *

The arms on all of my cars are on the top. Is this wrong? They're all hooked up and working.

(IMG:style_emoticons/default/agree.gif)

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BKLA
post Jan 5 2013, 08:06 PM
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My '70 had the same issue and the cables look original. My flapper boxes are new and the cables were short by about 1.25". I have a local vw parts store and bought a throttle cable rod end that I added to the cable. (Had one left over from the empi HPMX carb kit, so i only needed one extra.) That rod fit the brass barrel nut and made up the shorted distance.

I figured that it was just the fact that my car is a Frankenstein with heater boxes, tubes and other parts sourced from a number of parts cars:

-heater boxes are '73 2.0
-motor is '75 1.8 freshly rebuilt with back dated motor mounts and crossbar.
-heater tubes where from a '74 2.0
-flappers were two NOS parts that I had in my stash...
-new hoses from mikey914 aka 914rubber.com

I'm still looking for a blower fan to connect up to the tubes by the heads...

If you can't find out why it's short, try the throttle cable clamp rod....
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Spoke
post Jan 6 2013, 07:46 AM
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The cable ends on my car were cut when I bought it.

I got some wire of similar gauge and tiny U clamp from the hardware store to extend the cables.

The cable extensions don't have the special end but those aren't necessary to terminate the cable at the flapper valve.


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mepstein
post Jan 6 2013, 08:20 AM
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You could buy similar wire and find some barrel nuts that will clamp down on the smaller diameter. Once you have the length correct, give the end of the wire a twist to keep it from pulling through the nuts. 78" of wire needed but you could always start out with a little extra. Or pop for the $40 oem wire and be good to go.
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