Well crap...nicked aluminum heater line

[mijohnst]

In the process of replacing my heater core, I cut out the old heater core lines coming out and thought while I was at it I would also use my oscillating tool to cut off the old plastic heater core connects. Well, I wasn't careful enough and now it looks like I circumcized the end of one of the aluminum tubes that running to the back heater. I doubt without the flare at the end it's going to hold antifreeze.

Ugg... One more thing I didn't want to have to deal with. Any suggestions on how I should fix this? My thought is to go the junkyard and cut off about a foot of the tubing from a like Tahoe and somehow splice it together. I don't think I could braze under there because it's too close to the firewall. Maybe a compression fitting? Will that work with aluminum? Maybe just use rubber tubing to connect the pipes together?

One of these days I'm going to stop making dumb mistakes. :/

 

[OR VietVet]

It's a $25 heater core. Buy another one. Way less grief.

 

[mijohnst]

No, I didn't cut the heater core. I cut the tip (the flared end) off the aluminum pipe that connects to the rear heater. You can see it in the picture.

 

[wjburken]

In the process of replacing my heater core, I cut out the old heater core lines coming out and thought while I was at it I would also use my oscillating tool to cut off the old plastic heater core connects. Well, I wasn't careful enough and now it looks like I circumcized the end of one of the aluminum tubes that running to the back heater. I doubt without the flare at the end it's going to hold antifreeze.

Ugg... One more thing I didn't want to have to deal with. Any suggestions on how I should fix this? My thought is to go the junkyard and cut off about a foot of the tubing from a like Tahoe and somehow splice it together. I don't think I could braze under there because it's too close to the firewall. Maybe a compression fitting? Will that work with aluminum? Maybe just use rubber tubing to connect the pipes together?

One of these days I'm going to stop making dumb mistakes. :/

View attachment 238157

Oops! That’s definitely more than a nick.

That will not seal, that is for sure.

I am not sure I would try and splice that. The fewer splices/connection the better when it comes to coolant lines. I would try and find a whole replacement line.

 

[Doubeleive]

oopsie!, yes that lip makes the seal
option 1: replace the line
option 2: cut one off a junker and patch the end piece back on with clamps and a section of rubber hose

 

[mijohnst]

I can pull an entire line off of a junker but I think it's going to be a nightmare to pull one out. :/ Isn't it one continuous piece from the front heater core to the back one?

 

[Doubeleive]

I can pull an entire line off of a junker but I think it's going to be a nightmare to pull one out. :/ Isn't it one continuous piece from the front heater core to the back one?

I think so

 

[wjburken]

Short term, if you need to get up and running, you might be able to by-pass the rear and get some straight fittings that are used on a pick-up.

 

[OR VietVet]

I should have read that closer. Oh boy, what a mess. Still having fun working on your rig? Sorry.

I don't see one listed at RA, GM Parts Warehouse or GM Giant. Salvage yard I think.

The only other way I see it is to run a shunt of sorts. Have to use a length of hose with 2 new barbed splices, one at each end, and run it along the route of the old one. If all that is even possible.

 

[mijohnst]

I really appreciate the input from y'all. I don't see how I'm going to be able to replace the entire line in one piece and I can't find anywhere on the web of someone doing that. I think I'll go out to the junkyard and cut a 1 to 2-foot section from the same pipe, cut my pipe at the same length and then use high temp rubber tubing to connect them. I'll bulb the connection ends for a tighter fit and use small hose clamps to connect them. I'm going to try that and see how it works before I re-run that entire line.

Or something I just thought of... maybe there is another type of fitting I can use to connect into the heater core T connector that will allow me to use a small hose clamp instead of the snap-in. Man, that would be nice...

One day I'll learn...

 

[mijohnst]

Ok, I think I know what I'm going to try. I've ordered one of these types of connections and I'll just use rubber tubing to connect my original line to that smaller clip-in. Basically I'm still connecting the line with rubber tubing like I planned to do but I won't have to cut my line at all and I'll connect right at the junction.

 

[live2pull]

I would cut the end off at the wrecker and compression it on. The trick would be finding the fitting that fits.

 

[mijohnst]

I would cut the end off at the wrecker and compression it on. The trick would be finding the fitting that fits.

I ran to the local junkyard and cut off about 12" piece but how would you compress it on? Thanks for the suggestion!

 

[wjburken]

I ran to the local junkyard and cut off about 12" piece but how would you compress it on? Thanks for the suggestion!

I would take that piece to a hardware store or auto store and find some high temp hose that fits snuggly over the tubing and a couple of hose clamps.

 

[mijohnst]

I would take that piece to a hardware store or auto store and find some high temp hose that fits snuggly over the tubing and a couple of hose clamps.

Great minds think alike. I did that exact thing. I bought high temp rubber tubing that is snug around it with a few small hose clamps. I think it's going to work great. I'll put pictures up when I'm done.

 

[SnowDrifter]

Actually I think that might seal

IIRC the o-ring doesn't seal down that low

File the end flat then taper it so it doesn't pinch the o-ring on insertion

 

[mijohnst]

Actually I think that might seal

IIRC the o-ring doesn't seal down that low

File the end flat then taper it so it doesn't pinch the o-ring on insertion

I thought about it but I thought that the bevel needed to push up into the seal. I might try it and if it leaks go my patch route. Thanks for the input!

 

[live2pull]

I ran to the local junkyard and cut off about 12" piece but how would you compress it on? Thanks for the suggestion!

https://www.acehardware.com/departments/plumbing/pipe-fittings/brass-fittings/4338075

 

[89Suburban]

Actually I think that might seal

IIRC the o-ring doesn't seal down that low

File the end flat then taper it so it doesn't pinch the o-ring on insertion

That's what I was thinking too.

 

[wjburken]

Actually I think that might seal

IIRC the o-ring doesn't seal down that low

File the end flat then taper it so it doesn't pinch the o-ring on insertion

I thought about it but I thought that the bevel needed to push up into the seal. I might try it and if it leaks go my patch route. Thanks for the input!

If you haven't cut anything (more) yet, i'd give it a shot. What is there to lose?