Overhauling Heater/AC Box
With more than a little trepidation, I decided to tackle the heater/AC box.
I took the advice of a number of people on this board, and I took MANY photos of the disassembly. What follows is a blow-by-blow of the process. First, the molded fiberglass box is old and can be brittle, which can be problematic when popping off the clips that hold the two box halves together. The fiberglass broke out on several of the locations. I was able to fix those areas with a wad of JB Weld "weld stick" pressed into place. I drilled a few small diameter holes in the parent material of the box to allow for the JB Weld to "anchor" into the parent material. After it cured, I was able to use my drimmel tool to re-shape the area and dig out a new depression for the clip to grab. I think it worked out rather well.
Once I got past the leaves, pine needles, dirt, dust and miscellaneous trash, it was obvious that the heater core was junk. That began a whole new saga.
With more than a little trepidation, I decided to tackle the heater/AC box.
I took the advice of a number of people on this board, and I took MANY photos of the disassembly. What follows is a blow-by-blow of the process. First, the molded fiberglass box is old and can be brittle, which can be problematic when popping off the clips that hold the two box halves together. The fiberglass broke out on several of the locations. I was able to fix those areas with a wad of JB Weld "weld stick" pressed into place. I drilled a few small diameter holes in the parent material of the box to allow for the JB Weld to "anchor" into the parent material. After it cured, I was able to use my drimmel tool to re-shape the area and dig out a new depression for the clip to grab. I think it worked out rather well.
Once I got past the leaves, pine needles, dirt, dust and miscellaneous trash, it was obvious that the heater core was junk. That began a whole new saga.