Bad idea - copper in tandem with aluminum and other metals will not be
happy in the coolant system.

Stainless ...........  now yer talkin'.

I have a bead roller to use on the tubes for the future job, wouldn't trust
JB Weld to make a bead that could fail.  You could waste a many $$$ motor!

Randy Bergum
1990 Carat
Fullerton, CA

> [Original Message]
> From: Robert Harris <rdh24@CORNELL.EDU>
> To: <vanagon@GERRY.VANAGON.COM>
> Date: 11/1/2005 1:11:33 PM
> Subject: Re: Steel coolant pipe repair ideas
>
> Shawn,
> If you have any, standard 1.25" copper plumbing pipe is exactly the right
> internal diameter to slip tightly over the cut ends of the VW coolant
> pipes.  I had to cut down the steel coolant pipes in my 84 Westy for an
> engine conversion, and like you, was concerned about leaving them without
> some kind of flare or bead at the ends.  I cut a couple narrow rings of
the
> copper and slipped them on the steel lines with lots of JB Weld... forms a
> good strong bead.  No leaks in 20K+ miles anyway.
> best,
> Robert H
> 84 Westy "Busaru" - about to go into winter hibernation
> <www.people.cornell.edu/pages/rdh24/vw/index_vw.html>
>
>
> >The steel coolant lines on my '82 diesel Westy had the typical rust in
the
> >last 18" of pipe, so I cut this out and replaced with marine
coolant/exhaust
> >hose, sized to fit over the steel pipe. For now, I have double clamped
> >each joint, as they are prone to slipping, since there is no 'flare' on
the
> >pipe where it was cut. Now I have a friend facing the same issue no their
> >'85.
> >Ideas that have come up so far as: 1) welding a bead around the pipe to
> >simulate the stock flare. 2) Buying the expensive tool to create the
flare in
> >the pipe (way too expensive!).
> >
> >Any other ideas? The drawback with welding is having to remove the
> >whole length of pipe (and presumably the fuel tank as well). Unless I can
> >bend a wire around the end of the pipe and just tack it in place in a few
> >spots with the pipe installed...
> >
> >In both vans, the pipes appear pristine except for the rearmost 18", so
> >replacing the whole lot seems overkill. But maybe 1.5" hose the whole
> >way is a better choice long term? The marine hose I used is much larger
> >(very thick), so I don't know if it will fit in some of the tight spots.
> >
> >Ideas welcome...
> >
> >Shawn Wright
> >http://zuiko.sls.bc.ca/~swright
> >'85 Jetta D
> >'88 Westy 1.6TD 5 speed
> >  (see progress at http://members.shaw.ca/vwdiesels)
> >'82 Diesel Westy