Heater duct fabrication question

[bryancostanich]

Hi all,

I'm doing a buildup of a '72 FJ55. I'm currently rebuilding the heating system. I need to fabricate some custom (and some stock) ductwork. Has anyone done this? any material choices that they've worked with that have worked out? How do you go about it?

I've thought about getting some rubber sheeting, cutting, folding, and gluing together.

here's a picture of a stock piece i want to rebuild:

I also have to make a custom piece that goes from the squirrel cage to the heater (they're a mis-match set, so there isn't a stock part that would work, even if i could find one).

thoughts?

I also have to pick up some flexible hosing to hook everything up. i haven't been able to find any at the local auto parts store, but i'm thinking there might be some available elsewhere. something else i can use, etc.

 

[John Galt]

A heating and sheet metal shop will have a variety of round flexible ducts in different diameters and materials.

The piece illustrated could be duplicated by someone who makes neoprene wet suits

 

[bryancostanich]

the problem with neoprene though is that it doesn't last very long at all.

 

[PhilC64]

I just read on here somewhere that somebody used a tire innertube to form that piece.

 

[bsevans]

My heater duct cracked and had some pieces break off. I wrapped the heater duct with fiberglass mat and epoxy and it is much stronger than the factory original heater duct.

 

[thecrazygreek]

You can still buy that piece from Toyota or $OR.

Specter Off-Road-Land Cruiser Parts - Search On-186-05

$29.00

 

[mooker82]

Fiberglass....You can easily use heavy matting or felt to make your mold. Couple of layers of resin and cloth and it should be good to go and last a long time.

 

[bryancostanich]

good call on the fiberglass.

 

[Living in the Past]

You can still buy that piece from Toyota or $OR.

Specter Off-Road-Land Cruiser Parts - Search On-186-05

$29.00

The problem is that he has an FJ55 not a FJ40 which SOR shows as unavailable for all FJ55 with the pre 74 heater I've never tried it but the 74 and later heater duct looks close to the earlier just doesn't use a rubber boot. I don't know did the FJ55 do the same thing with the 74 model? Do away with the boot.?. Would a later heater duct from a FJ55 maybe work.

 

[bryancostanich]

John,

I would imagine, neoprene, under these circumstances wouldn't last more than a couple years.

Neoprene wetsuits need to be replaced every year. Granted, they see more stretching, abrasion, etc.