How I spent Columbus Day:

My t-stat cover gasket was leaking, and when I pulled it off, the cover was so eroded that I had to file it down to make a new flat surface. But I shaved so much off that when I tightened the bolts, the t-stat was sticking out of its groove far enough that the ear broke off the aluminum cover (Motorcraft RH-36). And the heater outlet nipple was severely rusted. So after checking with every parts store & the dealer, and finding that the pipe isn't available from anywhere, I picked up a cast iron cover from NAPA & a bunch of copper from Home Depot. A couple of hours later, I had something that I HOPE will fit...

UPDATE:
Apparently, there are some of the original fittings available again (Elbow E5TZ-18599-C ~$32) but my contraption is still working fine after 6 years & another modification.

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See also:
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Owner caption October 2007 · Photo 2040 of 5000