Retrofitting heater/defroster

[DanEC]

I think the hole saw for the two core lines is probably the best approach. If you have a dremel with the little sanding drums they would be nice to kind of slightly oversize the hole to clean the edges up and smooth them - you may have to get it in from the dash side however.

It may have been overkill but after I installed the heater hoses on my heater I put a heavy strip of 3M strip caulk around them at the aluminum to seal it up tight. It can be a little sticky in trying to mold it to a finished appearance but I found that by wetting my finger with detailer spray or spray wax I could tool it and it also cleaned any smudges off of the aluminum.

It's not necessary but I also fastened a metal strap to one of the upper heater case screws at the rear (dash side) of the heater and ran it up to the inner fiberglass panel in the cowl and secured it with a short screw. That made the heater mounting very solid. With just the 3 screws at the firewall it wasn't as solid as I wanted it to be.

Good luck

Edit - a picture being worth a thousand words - you can see the strap here. I had to be careful where I drilled for the upper mount.

[1795]

I plan on drilling a small pilot hole through the center of the marks on the template to center my bits, and then will follow up with the hole saw for the inlet and outlet hoses and 3/8" bit for the mounting screws. I do not have a dremel, but will use your suggestion of a rat tail file to clean up the holes. I like the idea of the additional mounting support strap, but it would be too hard to do now with all of the gauges and wiring in place. Heading out to pick up a few last supplies and if everything goes well, will start taking pictures and getting the project going.

The problem I am fighting is that this is the first nice day in a week, and the last for at least one to two weeks and I really want to take the car out for another spin....

Will keep everyone posted.

Jim

[patrickt]

Originally Posted by 1795

I do not have a dremel, but will use your suggestion of a rat tail file to clean up the holes.

Jim, over the years, when I need to make a hole to "just the right size" and in "just the right place," I prefer to use a hand file. Nothing will slip on you and it's very hard to make a mistake. And just ignore Chas., he always gets cranky on Friday nights.