64-66 Heater Upgrade - Thrift Air -to- Deluxe

[Frizzle Fry]

Actually, it should be better than deluxe when done since I went with a stronger blower motor than orig.

So my trusty ol' heater stopped blowin hot air in EARLY JANUARY

Me being me couldn't just replace the blower motor ....no I had to tear the whole thing down.

One thing led to another, and through research on this site (some good and some bad advice, but we'll get to that), I ended up converting my Thrift-Air box to a Deluxe heater.

What's the difference?

Four (or five?) basic things:

1. Deluxe has a larger heater core
2. Deluxe has an extra air flap in the box to bypass the core (allows for temp modulation)
3. Deluxe has the three-lever control panel rather than the single twist/push-pull know of the thrift-air
4. Deluxe has a cable-operated defrost/foot-box lever
5. Deluxe has a larger blower motor? (research suggests)

Heater core diff:


Air Flap:
Thrift (no flap)


Deluxe:


Thrift Dash:


Deluxe Dash:



Since I had a Deluxe dash panel and plenum laying around, all I needed to do was to figure out how to add the air-flap, bigger core, and bigger motor to complete my conversion. Simple right..? (notice it's now late March )


Start the tear-down:


This rusty plate is the block-off plate used on Thrift-Air heaters to force the air through the heater core. The Deluxe version is movable via cable:




Another view of the block-off plate:


Here you can see the upper cast AL piece has been made for either small or large cores. In this case the small hole is opened for the non-deluxe core:










Re-form block-off plate on brake:


Welded to SST rod:




Test-fit of Deluxe core after opening the upper:








Deluxe plenum and controls - pics for reference:


























Control levers blasted, sanded, and ready for electro-plating:








Raw plating before polishing:




After a very quick polishing:




Another thread suggest you can use a late-70's to 80's A/C blower motor/fan. Well that didn't work for me. Fan was too tall (and plastic).

Here's what ended up working for me (and powerful)
Motor and fan P/N's:


Now the motor shaft was too long, but I used a combination of the fan's set-screw (enough to hold alone) and a nut/washer as a spacer to snug it down with the nut:


The assembly fit the housing like a dream:


Blasted parts ready for paint:








SPI Epoxy brewing:




Hung up to dry:


Reassembly:








I picked up all new stainless hardware at Ace. I'd come this far...




















New gasket RTV'd on:


Back in the truck! I had been working far too many hours at work since Jan and was tired of the cold commute, so I installed it without the Deluxe control panel and plenum just yet. But WOW, this thing puts out the heat!!! (and it's the best looking thing under the hood )


I'll update as the rest of it comes together.

[Mathew21]

Wow great write up. Very detailed.

[Mikes66ChevyC10]

That was a great write up!! Thanks for posting!

[corvettejim1968]

wow great job im impressed with the detail better than new i bet.

[1963c-10]

Nice job on the heater system and great write up. The temp is based off the thermostat not the amount of air flow over the core though correct? The larger motor may flow more air, but the only way to make it hotter would be to increase the temp range on the thermostat.

[Frizzle Fry]

Thanks guys. Very happy with it so far (except the new paint smell).

A bigger heater core can flow the same volume of air at a lower velocity or a greater volume at the same velocity as a smaller core. Air velocity moving past the core is directly proportional to residence time (lower velocity = greater residence = more heat transfer).

So a bigger core does put out more heat.

The in-box air flap allows bypassing of the core to produce lower temps when desired.

[63burban]

Like your spray booth, nice job on the heater.

[Frizzle Fry]

These larger heater cores are around $90. Best price I found on the core, cables, knobs, and seal kit was at LMC. Though I'm not a fan of LMC, I reluctantly ordered through them.

I want to share with you guys what I found. The seal kit and the Deluxe core are both repackaged/relabled by LMC. Here's what was hiding under their labels:





One more thing to be aware of. I've seen others complaint about this: The heater core pipes are not in the same position as original, so the support bracket doesn't fit. I will fab up my own, but this needs to be addressed. Otherwise they will fail in time due to the weight and movement of the hoses.

[65 C20]

Frizzle Fry.
I was wondering about the heater core support bracket myself.
When I purchased my truck it was missing but it looked like a newer core.
I have ordered a support bracket from another member but haven't recieved yet.
I was hopeing to bolt it right on but may come across the same problem as you and might have to modify. Probably why it was missing.

[GMR-PERFORMANCE]

Now my truck came with the deluxe heater set up. Now I have not been able to find a core that will fit my set up. The lines are not the same. I have had mine repaired twice now and it started to weep again. SO if anyone can tell me where to get a 100% direct replacement heater core I would be very happy. I already ordered one from LMC and its it not the same.

[Frizzle Fry]

60-63 heaters are different than 64-66.

[1963c-10]

Originally Posted by GMR-PERFORMANCE

Now my truck came with the deluxe heater set up. Now I have not been able to find a core that will fit my set up. The lines are not the same. I have had mine repaired twice now and it started to weep again. SO if anyone can tell me where to get a 100% direct replacement heater core I would be very happy. I already ordered one from LMC and its it not the same.

Prior to my swap from deluxe to standard in my 63, I bought a NAPA heater core for the 63 deluxe heater and took my original Harrison tank to our local radiator shop. The used my original tanks and the core from the new one to make mine. Basically just recored the tank. Came out great and worked flawlessly. Cost around $45 in labor and $60 for the core. Theres a NAPA part # and pics about half way down this thread: http://67-72chevytrucks.com/vboard/s...d.php?t=548819

[GMR-PERFORMANCE]

Thanks I was hoping for the silver lining.. My tubes have been repaired and I have to say it sucks at this point the almuin seal is the fix. FING thing will weep and it drops on my floor ARGGG .

[benwah]

I want one of those trees that flowers truck parts.

[63 Rat]

Beautiful job! Very informative. Looks like the nicest thing under your hood now! Yeah, the parts hanging from the tree reminded me of the scene in the original Texas Chainsaw Massacre when they discovered the BBQ booth!

[88k5jimmy]

Where did you get the replacement rivets to reassemble the lever holder to the back of the face plate? Also, does anyone know what the factory screw looks like that attaches the face plate/entire heater control to the two tabs on the dash at the top? Mine only had one and I don't think it's the factory. I haven't found any replacements from aftermarket.

Thanks and nice write up.

[Macdaddy1]

Very nice job. I will eventually get around to installing mine and will use this thread as my go to.