Re: Distorted/leaking thermostat covers

[legendre]

quote johnyrude200:

I have been seeing many of them distorted and try sanding/lapping them down, but that doesn’t seem to work very well.

Are these housings steel stampings or aluminum / zinc castings? Warped steel can be a headache, trying to re-form a precision surface.

But if they’re cast, then you must have some flaw in your lapping process. Either you’re not going far enough, and they still have excessive warping – or a flaw in your tools / technique isn’t producing the desired flat and uniform surface.

As you’re lapping, do you follow your progress, checking with feeler gauges?