Rick1956
Jeeper
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- Location
- Edgewood, Washington
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- 81 CJ7, 258, SR-4, Dana 300, Dana 30, AMC 20
I couldn't post everything at once, so here's the continuation for the revised, version 2 defroster plenum.
After cutting another length of tubing, I fileted it into two pieces down it's length. I removed about 3/8" material from both legs, fashioned a couple of wood blocks to hold dimension and clamp it together with, and re-welded everything. Now it's rectangular tubing!
I thought the reduced channel size would make it more of a pain-in-the-<-BAD WORD-> to weld the 1 7/8" exhaust to, but it actually fit better. It was, however, a lot more tedious to shape them before they were welded because of having to match the square shape. As you can see the plenum height is quite a bit shorter (I forgot to measure it) from the original at the back. This eliminated what was showing at the bottom of the channel when the first one was installed.
After playing catch-up and giving it the matching oval exit holes, it got some paint and was installed. It's a much better fit!
My picky nature isn't yet happy with that revised plenum, but only for one reason: the round hose ends should have a little more clearance for the zip tie and the defroster hose thickness to have a really good fit. At some point in the future I'm sure I'll rebuild it again, but for now, what a nice, toasty defroster!
After cutting another length of tubing, I fileted it into two pieces down it's length. I removed about 3/8" material from both legs, fashioned a couple of wood blocks to hold dimension and clamp it together with, and re-welded everything. Now it's rectangular tubing!
I thought the reduced channel size would make it more of a pain-in-the-<-BAD WORD-> to weld the 1 7/8" exhaust to, but it actually fit better. It was, however, a lot more tedious to shape them before they were welded because of having to match the square shape. As you can see the plenum height is quite a bit shorter (I forgot to measure it) from the original at the back. This eliminated what was showing at the bottom of the channel when the first one was installed.
After playing catch-up and giving it the matching oval exit holes, it got some paint and was installed. It's a much better fit!
My picky nature isn't yet happy with that revised plenum, but only for one reason: the round hose ends should have a little more clearance for the zip tie and the defroster hose thickness to have a really good fit. At some point in the future I'm sure I'll rebuild it again, but for now, what a nice, toasty defroster!
