Date:         Fri, 3 Oct 2014 12:00:54 -0700
Reply-To:     Neil N <musomuso@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Neil N <musomuso@GMAIL.COM>
Subject:      Cooling System: tips from a newb POV
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Hi all.

As a newb doing a rebuild of the cooling system, thought I'd post what
I'm learning for anyone else in a similar position. Some or all of
this has been covered before, and apologies for a long post, but felt
that these might be of some use.

- give thought to hose clamp placement (thanks Ken W!); place for
easier access later
   on. If using spring clamps, try to place them so ears are away from
working hands.
- pipe under crank pulley; if coating it, consider powder coating.
When positioning it,
  newly applied paint will get scratched up. Dry fit coolant pump,
line up pipe, hose, 90º
  elbow. Coolant pump can be removed leaving these parts ready.
- clean all fastener threads really well!
- I chose to add sealant to outside edge of coolant pump and face of
big steel pipe to
  pump. In hindsight, an dowel in one flange to pump hole would help
line up parts so when threading the first fastener, the sealant
doesn't get messed up. Or, install parts concerned working from
coolant pump to thermostat ??
- consider using a slightly longer FLAPS available (??) hose between
pipe under crank
  pulley and 90º elbow. New part I got fit, but is **just** long
enough for two OEM spring
  clamps to cover. There is a small pin on under pulley pipe. I assume
its a stop for hose
  positioning.
- Likely not needed, or is "over kill" : dressing faces of various
parts to remove pitting-
  scratches. Most were worked against various grades of emery cloth on
my work bench
  but a piece of aluminum angle (sharp edges filed down), covered with
emery then
  crocus cloth worked well. (i.e. on coolant pump face where under
pulley pipe connects.
  New part but had minor scratches at that face) Caution; depending on
how it's done,
  one could incorrectly change the angle of the face. Especially if
part is aluminum.
- WD40 worked great for lube to help position spring clamps.
- fuel injection clamps can be used on smaller hoses to engine bay
coolant manifold
- brake parts cleaner is really useful for cleaning up parts for paint
or sealant.

I used Zero Rust paint to touch up exhaust "tin" (shroud). It's rated
at a higher temp, but I'm not certain it will take heat from exhaust.
It will likely hold up. I painted the coolant bottle bracket with
Tremclad. Not sure if that was a good idea (heat from shroud). Zero
Rust was used on the steel coolant pipes in engine bay.

If I think of more, I'll post it.

-- 
Neil n

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