Baystate Jeepers

Could use some advice / input on my heater core install. I got the leaking heater core out, but the $70 aftermarket core from the Crown outlet is a bad fit (new one is on the right) I have to decide whether to try to heat and bend the tubing to fit or return it and buy an OEM one for much more $$$. I've seen posts showing how aftermarket ones from NAPA are a bad fit too. Is bending the tubing a bad idea? I was thinking of heating it with a MAP torch and gently bending it over some round tubing. I obviously don't want to do anything to that would force me to do this again anytime soon!
Also, I followed some internet advice and didn't completely remove the dash. I used some straps to hang it from the roll cage and I didn't have to remove the steering wheel or air bags. Still left enough room to remove the HVAC assembly.

I just called the crown outlet and talked to Jeff. He says everyone that every aftermarket one they have ever sold comes that way and that they're aware of it and know that shops are able to install them. He's going to try to figure out what they do to get them to fit and let me know. If anyone has some firsthand experience, let me know!

it almost looks like you could cut the pipes and make it fit, by soldering on some new pieces (45 degree angle joints and misc pieces). Or remove the original pipes and graft them on to the new core? Maybe something a radiator shop could do quick and cheap

If you heat and bend, just be careful not to use too much heat! Doesn't take much to melt solder.

I ended up putting it in a vice with some wood, heated it away from the solder and it bent pretty easily. It left a tiny kink but it's no biggy. Then I had to do some handy work with a dremel on a misplaced mounting bracket on the tubes. Still have to drill a new screw hole, but it pretty much fits now. The little extra work is worth saving the extra $300 an OEM core would cost - assuming it lasts!

Holy crap. Glad you made it fit. VERY glad I have a YJ. The whole heater box is held in with 6 bolts and comes out from under the dash.

I saw that too Joe : Im thinking what moron has you remove the dash like that for a heater core . I dont even have bolts, I have snap clips that hold the half's of the box together. The worst part for me (CJ) is the heater hoses are under the battery tray. FjR68