Some progress on Billy's heater valve.
The old one was rusted through as well as being stuck and badly deteriorated seals. After lots of searching could not locate a good replacement.
This is as close as could be found, and the original shown disassembled.https://picasaweb.google.com/lh/photo/NhQLfz-fFo6fjmwuhptD6tMTjNZETYmyPJy0liipFm0?feat=directlink
The plan is to take the new one apart and modify it to look and work like the old one with both hose barbs pointing straight out. Also reuse the square mounting plate from the original.
First I disassembled the new one and cut off the barb from the side port. Then made a die to clamp around the valve and allow me to form the tube end into a birdsmouth or saddle same as the original was.https://picasaweb.google.com/lh/photo/lJGYe6OlMX80B0A2cdTgBNMTjNZETYmyPJy0liipFm0?feat=directlink
Then using a body hammer with a radius I formed the tube (only partly done in this picture). https://picasaweb.google.com/lh/photo/9gzXZTmKkqF8i41o5gMQN9MTjNZETYmyPJy0liipFm0?feat=directlink
Finished by laying a piece of 3/4" rod in and whacking that with a mallet.https://picasaweb.google.com/lh/photo/MPwYvxSjVZmOouRD4sCc4dMTjNZETYmyPJy0liipFm0?feat=directlink
Then made a new nipple from a piece of bar stock. Not shown but I also cut off the other one (it was 5/8") and made a new 3/4" nipple for it as well.https://picasaweb.google.com/lh/photo/mSh9aoi91tdSoSUyBNz0fdMTjNZETYmyPJy0liipFm0?feat=directlink
Finally silver soldered it all together and cleaned off the flux.https://picasaweb.google.com/lh/photo/cbeqxe9W_DSdX--qJVFlLdMTjNZETYmyPJy0liipFm0?feat=directlink
Next I drilled and tapped the new valve spool for the handle retaining screw (new one only had pressed on handle).
Still to do is reassemble the valve and figure out where to file the flat on the valve stem for the handle so it operates properly.