Reply to "Erica needs to get hosed....."

Update!

New evap core is finally in place in the tin, and in the car! Working to get external AC connections made!

All I can say about this job is that nothing fits like it did before. Nothing. Hoses that I cut for the heater section now are 1/4-3/8" too short. AC hoses don't fit quite right. I did have to bend the new evap connections just a tad to get clearance of the fresh air section of the late style box! No way around it. It was either bend the tube or no fresh air control!

The one thing that did still fit is the condensate drain hose.

It should be noted that the later style air box, has a one piece bottom section, no seams, with a half to 3/4" of depth to collect water in! One fellow member was relaying stories of his wife's feet getting wet every time he turned a corner...... I am presuming that the early boxes may have a seam that leaks at low levels of water??????

While the new evap core fit in the box physically, the dimensions of the mounting brackets (end brackets) changed slightly more narrow, and the core itself moved to the rear of the box by 1/8-1/4"! This makes putting those pointy little screws back in place a risky task!!! No less than 8 screws needed to be "de-pointed" and made smooth. I also installed washers to take up a little more space! The new core is aluminum, so won't take much to drill into it!!!!!!!

I had to relocate one of the two mounting screws for the core, and make a new hole for the tube that the temp sensor probe fits into. The stock hole didn't align with the new core at all. Had to drill both the case and the core end to accommodate the brass tube insertion to the area where the two rows of fins meet.....anywhere else, you'd be buying a new core once again!!!!

I'll throw up a couple of pictures....of the work.....

First, what got me into all of this mess! The crack...or cracks!!! Both sides of the "Y" look cracked.....
Ciao!
Steve