Air Flap - 2.0 L

[RussellK]

I believe it is called the Air Non-return Flap. There are two on each side of the fan housing (or is it blower housing) My guess is they are pretty critical or they wouldn't be there. That said one of them is damaged. Does anyone have a source for replacements? How about a repair? I could make a new one out of a piece of A coil but I don't know if it would work as well as the original. Mine has half the hinge missing maybe make a new hinge and pop rivet it on? JB Weld it?
-Russ
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-Russ
'77 Westy

[vwlover77]

I don't think they are critical to engine cooling. They are only there to keep the heater booster fan from wasting its effort trying to cool the engine instead of blowing through the heater boxes at idle when the output of the main cooling fan is low.

Mine are missing completely, I now know! I hope the extra engine I just picked up from our own Sean Gallagher might have them.

If you can fab something up, it should be fine.
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Don

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78 Westy
71 Super Beetle Convertible Autostick
99 New Beetle

"When we let our compassion go, we let go of whatever claim we have to the divine." - Bruce Springsteen

[RussellK]

Thanks- That makes sense now that it's explained. I kept wondering why would they need to block air from entering the housing. Never gave the heating a thought.
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-Russ
'77 Westy

[Mark]

[shameless_plug]I've been working on developing these as reproduction pieces.
They will look, fit, and be constructed as the originals.[/shameless_plug]
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'64 Sedan
'74 Westy
aka the "Hoover Bit" repro guy

[RussellK]

Hurry!
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-Russ
'77 Westy

[tristessa]

Mark, cool beans on the reproduction, especially the look-fit-construction bit.

A functional repro isn't hard to make, we had to make one for each side of the fanshroud on Joseph's '77. Used a pizza pan from Dollar Tree and a couple finish nails .. work fine but they look nothing like the originals.
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Remember, only YOU can prevent narcissism!

LongCat is loooooooooooooooooong.

[Sylvester]

[LeeE]

I made these from a cat food can



The picture doesn't show all the bends, but they were easy to make. I used a finishing nail for the pin too. After the photo I tapped them with a rubber mallet to get the dish/contour aound the edges to fit a little better.

Hmmm, hope they don't smell like cat food.

[VWBusrepairman]

I am also running without these small non-return flaps. I would say they are critical at idle when the aux. fan beats the cooling fan, but would say they are negligable when the cooling fan is at 2500 RPM or so. I have a fan with the pieces in place and thought about replacing the entire housing since my current "GE" housing is damaged enough that the flap pin cannot seat. I think the "GD" housing is the one with a good set.

I can see if any of my other shrouds have a nice pair of non-return flaps this weekend and follow up with you.

[pb24ss]

[Amskeptic]

I have mangled a couple of pie tins to make those things for customers on the itinerary.
Two fabrication notes for you:
Keep the hinges short little ears like the factory did. This keeps the friction down to a bare minimum.
Make sure the hinges fit accurately between the ears of the fan housing hinge pin bosses. The flaps must not be allowed to move sideways too much or they will hang up and stick
Do tap the plates enough to make an impression of the outlet holes. This will help them seal and help them learn to stay centered.
Check that at full-gravity the bottoms of your new flaps are still just above the bottom of the fan housing ducts or they'll hang up.

How many fabrication notes is that?
Colin
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[pb24ss]

it sounds like you've got it down, Colin. when can we expect your first run of flaps to be available in the classifieds?
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78 P22 Westy

[Amskeptic]