DIY Thermostat Gasket?

Post by **MoVolvos** » 26 Aug 2020, 23:39

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Thoughts on making your own thermostat gasket in general? Posted here as it was done on an XC90.
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Post by **bmdubya1198** » 31 Aug 2020, 22:30

I'm sure it works well enough if you're in a pinch, but when the right gaskets are so cheap, I wouldn't bother. I don't know the science behind the material, but I'm not sure I would replace a steel gasket with a paper one.

Post by **Roger_850T** » 04 Sep 2020, 18:27

I would not do it.

My biggest peeve is when I fix something, and I take a shortcut, then I end up having to do it a second time, to do it right. With my luck, this would be one of those things. For a $5 gasket, or even a $50 gasket, I'll use the factory part, do it right, and be happy with it. (If I consider the cost of my time having to do it a second time, the gasket is always cheaper!)

Roger

Post by **cn90** » 04 Sep 2020, 18:56

Actually this paper gasket (between the UPPER and LOWER housings) is not sold separately. You have to buy the entire Wahler Tstat assembly for $100+.

Sometimes, people have coolant leak at let's say 60K, then making this gasket makes sense.

However, if the leak happens at 110K etc., time for new tstat and ECT. I bought the Wahler tstat assembly. Since I didn't want to remove the PS Pump, serp belt etc., I replaced only the UPPER housing + new gasket + new tstat + new ECT. Basically transplanting the new parts over. I wrote it in forum if people need the info.

Post by **SuperHerman** » 07 Sep 2020, 15:05

I have made countless gaskets for tillers, mowers, cycles and Volvos. I have a collection of various gasket material in rolled form. Material can be sourced from NAPA or others.

It is not fun and it is time consuming, but sometimes it is required. I have never had a failure, but I use the correct material for the application.

Generally, I would not replace a metal gasket with a paper one.

Post by **cn90** » 07 Sep 2020, 15:49

1+,

The metal gasket is between the LOWER housing + engine block. No need to replace it.
In the P80 cars (850, S70 etc.), this metal gasket lasts the life of the car.

The paper gasket is between the LOWER and UPPER housings.
This one can be made from the correct material.

Post by **SuperHerman** » 07 Sep 2020, 18:54

Clean the original gasket as best you can and dry it. Use it as a template and trace onto gasket blank material. With a sharp razor blade or equivalent coupled with a straight edge make your cuts. Several passes may be required if thick material. Go slow on the curved edges free hand. For bolt holes I use a paper punch.