Biohazard

First order of business:
Received the new grille today and I'm very pleased. It is exactly as you would have expected from the pic above in that there is the one crack in the surround (easily fixable) and some very light bubbling in the chrome. No big deal there. The park lamp is actually in very nice condition aside from the crazing in the lens.

Labor update:
Finally got my A/C plates back from sandblasting and got right to putting the HVAC box together. I'm using the DMT kit. Nice stuff but I opted out of using globs of caulk to seal the little gaps and instead applied little bits of roof flashing. I had a roll of it and it is very sticky.

So I started with that vent flap - the one that's a real pill to get out.
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Cleaned it up.
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...and here's the finished product.
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Here's the HVAC box all plugged up
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Closer...
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All the insulation panels glued in place.
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The inner panel.
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Tested the evaporator - it seems to be air-tight.
Marinated the drip pan in ammonia for 48+ hours, buffed it down with steel wool, then I soaked it in a chemical rust converter. Being a double-wall pan makes it tough to reliably clean but my nose tells me its not impossible. Think I'm gonna paint it, too. If I do, that'll slow the reassembly but...no rush.