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My Fuse Box Relocation and Cleanup Project - Part 13

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turbosax2

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Nov 19, 2006
Mechanicsburg, Pennsylvania
Because I got rid of the heater and FIAV I had to modify the water pipe and thermostat housing. For the thermostat housing, I used a hammer and a screwdriver to smash the nipple up on the inside of the housing. I used vice grips to rotate the nipple in the hole so I could smash it up all around, then I was able to rip it out in 1 piece. The welder had to turn an aluminum rod to make a little insert to weld in there so it wouldn't warp the gasket surface. Then he grinded it down to make it look nice. I cut the little tube off the water pipe and cleaned up the surface. The welder patched this hole up with no insert. He had some issues because of the brazing material or whatever that was left on there but he got it straightened out and grinded it down too. I also cut some unneeded metal off of the coolant overflow bottle bracket, brake fluid reservoir bracket, and the bracket the clutch line attaches to.

Why didn't I cap off the coolant nipples/lines with rubber caps?
1. Welding looks cleaner.
2. I had a rubber cap (that was specially made for capping coolant lines) burst open on my brother's car and sprayed the whole engine bay with coolant - not fun. Welding doesn't leak.

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