Yesterday, getting the expansion valve off of the back of the evaporator, I had to mostly remove the entire under dash box. Was trying to leave the heater hoses alone, as well as the evaporator return line. Gave up on that, disconnected and plugged the heater hoses, got the evap return off, and removed the whole thing. Thought that reassembly would be easier on my bench, instead of upside down under the dash. It wasn’t.
The ******* for the drains, JB Weld seems to be holding. But pretty much every screw holding top to bottom, the plastic is cracked, brittle, and falls apart when touched. The assembly screws are all machine thread, with brass female thread inserts embedded.
Screw at front left is an example. It’s holding, for now, with no torque, barely finger tight, and the plastic is visibly cracked.
Because Power Tour is Sunday, I decided I’d bodge it together as best I can. I started making two sheet metal plates to hold the sides together with some strength. One is on the bench.
The motor mounts in the middle, driving two squirrel cages. The two inner screws looked ok. The outer two are gone. I started making two steel straps to hold the motor. Didn’t even make it to test fitting the first one, when more plastic bits broke off, including where I was going to attach the end of the strap.
A collection of the plastic bits that have broken off.
So, I give up. This plastic is just too compromised and brittle, it breaks off pieces every time I touch it.
I made some 1/2” copper plugs for the heater lines in and out.

Tomorrow I’ll get a bag of zip ties and tie up the hanging bits. The A/C lines will be capped and protected. I’ll order a new under dash unit to replace this one, and I’ll fix it when I get back.
Tulsa without A/C sounds lovely.