aaddpp

Some time back, I changed the the cooling system hoses that run to the steel y-pipe (928 574 106 03) found on the passenger side of the engine bay (LHD). I saw the pipe was not in great shape, but until I pulled the engine it was not apparent how bad it really was. The oxidation of the pipe had caused pitting and bulges which made it impossible for the hoses to seat properly, resulting in a slow leak. Whether related of not, the car actually ran hotter after the hose swap - top white line instead of middle. I thought about replacing the pipe, but $250 for new was a bit pricey, plus I feel there are plenty of other places where this kind on money is better spent on my car. That left the DIY refurb route...here's a few photos showing the process I followed.

Before Shots - note the rust, pitting, and scaling


http://www.flickr.com/photos/51967142@N00/6016439263/
http://www.flickr.com/photos/51967142@N00/6016990492/
http://www.flickr.com/photos/51967142@N00/6016440363/
http://www.flickr.com/photos/51967142@N00/6016993460/

After Cleaning - I used a coarse wire wheel on a drill...pitting becomes more obvious now

http://www.flickr.com/photos/51967142@N00/6016995210/
http://www.flickr.com/photos/51967142@N00/6016994916/

JB Weld - applied and allowed to dry over night

http://www.flickr.com/photos/51967142@N00/6016444343/
http://www.flickr.com/photos/51967142@N00/6016446607/

Post Sanding - I used a thin belt sander belt which I cut and then pulled back and forth by hand...the visible patches of JB Weld are where the pits were filled in.

http://www.flickr.com/photos/51967142@N00/6016998546/
http://www.flickr.com/photos/51967142@N00/6016998954/
http://www.flickr.com/photos/51967142@N00/6016999682/

Painting - mineral spirit wipe down, primer, primer sealer, aluminum colored paint, and clear coat

http://www.flickr.com/photos/51967142@N00/6017001834/
http://www.flickr.com/photos/51967142@N00/6017002150/
http://www.flickr.com/photos/51967142@N00/6017002462/
http://www.flickr.com/photos/51967142@N00/6016451399/
http://www.flickr.com/photos/51967142@N00/6016452411/
http://www.flickr.com/photos/51967142@N00/6016452747/
http://www.flickr.com/photos/51967142@N00/6017004642/
http://www.flickr.com/photos/51967142@N00/6016453413/
Total time to do this project was about 1.5 hours over 2 days since I had to wait for things to dry. While a few pits are still visible the overall surface is far smoother and I'm hopeful that the hoses will seat better on the pipe this time around.

Lizard928

I had one that had worse pitting than that. I checked for holes back where the pipe sealed onto it and didnt find any.
I then had it sand blasted and powdercoated. I didnt have one more problem after that.

F18Rep

Good thread, thanks...Bruce

Jim M.

I have three of them in my workshop, all in worse condition than what you started with. Yours looks like a good solution. My original plan was to reproduce it with copper. "Should" never have a corrosion problem again.

aaddpp

P/C would have been my first option, but I don't know any shops local. I am cautiously optimistic about my refurb since the paint laid down really nicely, though its never going to be as resilient as P/C.



I like the idea of rust free. Would you use the type of tubing found at a local hardware store, or is there something else?

Lizard928

making out of copper is a bad idea......

If you do it, use stainless.

Jim M.

making out of copper is a bad idea......

Please explain?