In a message dated 07/07/2009 9:39:48 P.M. Eastern Daylight Time,
LISTSERV@GERRY.VANAGON.COM writes:

        Andy, did you look at  the photos I sent on my Picasa page ?
_http://picasaweb.google.ca/FCondelli/FrontHeater#_
(http://picasaweb.google.ca/FCondelli/FrontHeater)      They are not as complete as I would like but I'm
still working on that  page.

    The foam seals on the flaps originally covered the  entire flap.  All
that is really needed is around the perimeter where the  flap touches the
edge of the box to make a seal.  Remove all the flaps from  the housing.  One
set of flaps will require removing the glued on cover  plate which can be
reinstalled with small screws, the screw holes are already  there.  All the
others can be removed by discovering the way, it's a sort  of puzzle but if you
study each location you will see how they are to be  removed.  Eventually I
will get photos of that operation.  Remove all  the plastic centre pieces
on all the flaps and discard.  Remove all the old  glue that is left from the
original foam.  Get "Weather Shield" peel and  stick foam insulation for
use around windows at the Home Depot or similar place,  1/4" T x 3/8" W and or
3/16" T x 3/8" W. Get both sizes and see which works  best.  I think I used
the thinner thickness on the flaps and the thicker  one around the motor
and heat exchanger.   Install it around the  perimeter of each flap where the
flap will touch the edge of the box on the side  where the old foam was.
Re-install the flaps.  Use the same peel and  stick insulation around the
motor and heat exchanger in the same place where it  was after removing the old
one of course.  The two halves of the  heater box is held together with 11
clips.  If you look carefully you will  see there is a specific location for
these 11 clips.  No glue or screws are  needed unless the casing has been
damaged.  These clips are available from  VW or I have them in stock.  The end
of the motor with the exposed bushing  needs to be protected.  Use a
suitable sized bottle cap glued in place  with silicon sealant.  Put some light
machine oil on that bushing before  installing the cap.  You need to test the
motor on all three speeds after  it has been positioned in the casing half
where it belongs and before  reassembling the box to be sure the ballast
resistor is good.  That's what  makes the fan have three speeds.  If the ballast
resistor which is inside  the box is bad now is the time to change it.  It
must be ordered form VW or  some other supplier who has it.  I get them from
VW as I need them, no  stock here.  To do this test you need a 12v power
supply, the fan  switch and some wire.  Ground from the 12v power to ground on
the  motor.  12v to the input of the switch.  Wires from the ballast
resistor to the switch.  Wire from the ballast resistor to the  motor. Switch all
three positions.  Low and Medium speeds pass through  the ballast resistor,
High speed is direct.  If you need more help you  can phone me at
613-256-6763 between 8am and 6pm.

>>>>>>Wow, I'm in Albany, NY and I received my  parts in one day time with
free shipping from euro parts/parts  direct.

It seems the foam from where the old heater fan sat is worn  out. I'll cut
and stick some new foam around the many curves and then set the  new heater
in (Mele). Is it ok to hook up the wires to the fan and switch,  hook the
battery up and try it out on all three speeds even though so much  more is
unplugged from the dash and speedo?

I've seen people mentioning  to put foam on the vent flaps. Seems it was
there before but mine must have  disappeared over the years. What should be
the thickness of the foam be and  does it go on the hole flap?

Assembling the two piece heater plastic.  Should I reglue it and put the 4
clips back on, or just the 4 clips or/and use  machine screws around the
perimeter?

Last but not least, did someone  mention glueing some kind of cap to the
back of the motor to keep dust from  getting in?<<<<<<<<<

Cheers,

Frank  Condelli
Almonte, Ontario, Canada
'87 Westy & Lionel Trains (_Collection for sale_
(http://frankcondelli.com/trainsal.htm) )
_Frank Condelli &  Associates_ (http://frankcondelli.com/busindex.html)  -
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
_Vanagon Stainless Steel Exhaust  Systems_
(http://frankcondelli.com/exhaust.htm)
_BusFusion_ (http://www.busfusion.com/)  a VW Camper  camping event,
Almonte, ON, June 11 ~ 14,  2009