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Ok, finally finished the PITA heater and evaporator core installation. My AC box was cracked in several places and Bubba had put it back together with lag bolts. Pulled it all out and I guess they had never heard of the rebuild seal kit. Anyhow, got a new heater core and evaporator core and they both fit fine with no problems and the seal kit from Doc Rebuild. When I got it all bolted up, there was a small gap in the center against the firewall, like it was bowed out from the firewall. There is no factory bolt to put there so I packed it with strip caulk. Is this normal on any others? I was tempted to drill it and put a bolt there to pull it up tight to the firewall but there is no play in it. Any thoughts on what caused this?
Also, on the condensation drip hole beneath the ac box, I understand you can't buy the original tube anymore, so I took a 1" bushing and screwed it up into the hole and stuck a brass air fitting on it (I didnt have the air hose repair piece or I would have used that) and slipped a hose over it to let the condensation water clear the frame. I used 3M weatherstrip adhesive on the threads of the bushing to secure it to the fiberglass ac box. What do you think? Bubba is still alive and well?
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