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My Heater box (HK) is leaking and I don’t think it is and issue with the core. The leak appears to be from the connection between the external valve and the 5/8" copper pipe exiting the heater box, the leak is coming out the drain The external valve connection is a compression type seal between the heater valve internal taper, the heat exchanger pipe and the plastic heater box taper with what may have originally been a square section 'O' ring. I have tried to replace with 2 off 5/8" x 3.5mm section 'O rings and no joy. Anyone else had this problem, is the original 'O' Ring available? Thanks Tony Edited by user Monday, 6 April 2020 3:58:38 PM(UTC)
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Generally the leak is due to corrosion in the alloy housing. nothing will fix it except a decent sealant, with or without the o ring.
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Originally Posted by: Tonyl66  My Heater box (HK) is leaking and I don’t think it is and issue with the core. The leak appears to be from the connection between the external valve and the 5/8" copper pipe exiting the heater box, the leak is coming out the drain
The external valve connection is a compression type seal between the heater valve internal taper, the heat exchanger pipe and the plastic heater box taper with what may have originally been a square section 'O' ring. I have tried to replace with 2 off 5/8" x 3.5mm section 'O rings and no joy.
Anyone else had this problem, is the original 'O' Ring available?
Thanks Tony I dont think you can buy the seal new but you can make one easily. Mine had a small section of heater hose maybe 8mm long and someone had tapered the ends of the rubber to suit the tapers in the valve and heater box. Didnt leak. When you bolt the valve to the heater box the rubber seal should squash inwards and seal, if you've made it long enough. 
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Originally Posted by: RigPig Originally Posted by: Tonyl66 My Heater box (HK) is leaking and I don’t think it is and issue with the core. The leak appears to be from the connection between the external valve and the 5/8" copper pipe exiting the heater box, the leak is coming out the drain
The external valve connection is a compression type seal between the heater valve internal taper, the heat exchanger pipe and the plastic heater box taper with what may have originally been a square section 'O' ring. I have tried to replace with 2 off 5/8" x 3.5mm section 'O rings and no joy.
Anyone else had this problem, is the original 'O' Ring available?
Thanks Tony I dont think you can buy the seal new but you can make one easily. Mine had a small section of heater hose maybe 8mm long and someone had tapered the ends of the rubber to suit the tapers in the valve and heater box. Didnt leak. When you bolt the valve to the heater box the rubber seal should squash inwards and seal, if you've made it long enough. It ended up being a leak at the soldered join between the tank/core and the copper nozzle that connects to the heater valve so I resoldered this. For the seal beteen the valve and the heater body , I modified an 'O" ring with a 5mm cross section by grinding a taper on each site of the O ring. It sealed up fine with no sealant, the section of hose with a taper on each side is a good idea. Edited by user Friday, 10 April 2020 4:58:03 PM(UTC)
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