Heat Exchanger Flat End Cap Fix

[Rob Schepis]

Is your heat exchanger cap weeping at the outer perimeter?  Is it “flattened” from years of over-tightening?  It is important to put the “concave” back in the cap if it has been over tightened over time and flattened. Think of the cap as a big lock-washer as you “snug” it up. If it´s too flat you will crush the center gum washer before putting any sealing pressure on the outer perimeter.

Here’s the fix in lieu of replacing the cap:

Find a flat solid surface.. Find a piece of pipe or a pipe fitting with about a 3.5-3.9″ ID so only the perimeter (outer edge) of the cap lays on the pipe or fitting. Lay the cap on it. Find a socket that fits the center section of the cap, about a ¾” ~1″ OD.  Get a hammer and make your “flattened” old end cap concave again to~ 3/32″.  It will now have it’s “lock” or “spring return” back.  A smear of Rectorseal on the gaskets at reassembly is always good.

Here’s what I used

Ready for impact

Before & After

3 users thanked author for this post.

jucaribu, Michael Starr, Bill Stenger

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[Rob Schepis]

Yes Dan, works well.  Always a good thing when the guy “at-profit” tells you how to fix something rather then selling you a new one..

[Dan Stewart]

Thanks for the tip.  Looks like a simple way, to fix a problem.. DS

[Author]

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