OEM Hayward heater header gasket not fitting

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VanShunt

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Jun 3, 2017
8
TX
Hello! While redoing the plumbing lead into my Hayward HD400IDL2 heater this weekend to fix a small drip leak, I thought to replace the heater's bypass valve and flow control thermostat which required removal of the header. The bypass valve kit came with a new gasket, but it was too large by about 1/2-1" as pictured. I called around and found a Leslie's that carried the part (HAXHOR 1930) only to discover it, also, was too large. The existing gasket has the same problem, so I am 0 for 3 and cannot get my pool running without a solution to get the heater back together. It's very tedious as the gasket and thermostat must stay in place while trying to line the header up with the 10 bolts on the face of the heater, all while the header is connected to one of the hoses leading into it as there is not enough room to do so once it's back on the heater. Has anyone encountered this type of issue? Any advice (aside from buying a new heater :scratch:?
 
Welcome to TFP!

I would drop one of the rings in boiling or near boiling water for a minute or so. Most synthetic O-rings will shrink when heated.
 
Thanks John & James. I did try the boiling one of the o-rings twice (about a minute each time) but did not notice any shrinking afterward. After researching more on that trick, I understand most the shrinking happens from lost oil/etc. which a new o-ring wouldn't have. I can try some vaseline to hold it in place--the trouble is one wrong move or bump when replacing the header, and either the o-ring pops out of place or the thermostat falls out.
 
Try soaking in ice water to get it to shrink. Use some silicone gasket sealant to hold it in place.

Are you sure that the thermostat goes like that?

Is that how it came out?
 
JamesW said:
Try soaking in ice water to get it to shrink. Use some silicone gasket sealant to hold it in place.

Are you sure that the thermostat goes like that?

Is that how it came out?
Click to expand...

I'll give the ice water soak a shot and try some sealant as you suggested.

Just checked the manual--you're right, the flange on the thermostat should be behind the bypass! I was obsessing so much over the o-ring I missed that. Thank you James.
 
Just to close the loop on this, I was able to get the gasket seated after putting a generous coat of silicone in the groove it sits in on the header and manipulating it until no part was sticking out. It was also a major help to not have to worry about the thermostat falling off while situating the header after placing it behind the bypass valve--thanks James for catching that. Reinstalled with unions in the PVC leading into the header's plumbing for easier service next time around.
 
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