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I have seen only Heater box rebuild efforts and descriptions on the internet. I am wondering if anyone has rebuilt the A/C Box on the firewall. As these components continue to age, I am guessing that more people are going to have similar problems with this box and would appreciate a guide on restoring them.
My problem is that these parts are not available for purchase unless you buy a scrapped/used part that will have the same wear and tear. as you can see in my picture, the blower box has rust pitting and some pin holes. the shelf that supports the foam gasket has also partially rusted away. How would one go about repairing this?
I was thinking of sandblasting (gently) and filling the pits and holes with metal epoxy. then sanding it down. possibly re-welding a "shelf" replacement...
Hey. I'm actually rebuilding the heater core box for a non-ac car right now. I'll be posting many more photos on my blog over the weekend. I'm sure this will be helpful to you. Here's some pics of rebuilding it.
This is the inner fiberglass box under the dash. Cracked and stressed fiberglass . Drilled out the mount, bought new ones as the studs we're bent and stripped. Drilled the cancer out with a Dremel melon baller thingy. Would up cutting that section out and staging it with toothpicks. Used JB Weld to situate everything. Had to keep this edge as straight as possible as it was bending upwards prior to me cutting it out. Cardboard and masking tape are JB Weld's best friends here. Recreated the original contour and built a wall. Filled it in three different processes to be sure the JB Weld was completely cured. Next steps are to reshape the holes and level the edge.
I have restored these before and other than the outer housings which I am mostly concerned with. ANY internal parts that have have some rust or pitting get media blasted and repaired using current types of epoxy adhesives and then painted. Seeing how they are not able to be seen...I do not get to worried on how good they look other than making sure their FUNCTION is intact.
A/C Box rebuild?
