techg8
01-28-2009, 05:10 PM
So I didnt want to ante up the $130 for an AC delete box for my 72 Skylark. But I wanted the Evap box gone, out of my way.
I was inspired by some DIYer posts on the board with a pic of an A/C evap box that had been "modified" into an A/C delete box.
So here is what I did, for those who want to try it.
I scribed a horizontal line around the evap housing the same height as the blower motor mounting surface. I used a digital caliper fixed at the correct dimension and used the mounting surface of the box as the guide. This got me most of the way around, and I was able to eyeball the rest.
(Another good idea I had that I did not try was to put the housing in a tub, mounting side down, then fill up with dirty water to the appropriate level. Pull the housing out, let it dry and use the water mark as your scribe.)
Anyhow, once scribed I used a fine hacksaw to cut and limit the fiberglass dust.
Once cut, I bolted my two delete pieces together and laid them on a fiberglass mat, cut side down. under the mat is a plastic bag. Then I applied the resin/activator mix to the mat at shown in the pics. Just enough to create the flat area I need to create my delete.
After it hardens, remove the plastic bag and trim the mat about an inch wider than the resin you applied.
Use the resin/activator stuff to glue the mat "fringe" to the inside of the delete housing, being sure to fill all the mesh, get it as airtight as you can. Let it harden.
I did some rough bondo work on top of the delete box (I am not all that worried about the best appearance, but If you put attention to this I am sure your results will be great).
Finally some paint, and I have my Delete box.
$13 for a fiberglass mat kit, and not too much bondo and paint. So lets call it $25 and I am good to go! Thanks to the DIYers out there who share their ideas! The concept was not mine but this was how I accomplished it.
I was inspired by some DIYer posts on the board with a pic of an A/C evap box that had been "modified" into an A/C delete box.
So here is what I did, for those who want to try it.
I scribed a horizontal line around the evap housing the same height as the blower motor mounting surface. I used a digital caliper fixed at the correct dimension and used the mounting surface of the box as the guide. This got me most of the way around, and I was able to eyeball the rest.
(Another good idea I had that I did not try was to put the housing in a tub, mounting side down, then fill up with dirty water to the appropriate level. Pull the housing out, let it dry and use the water mark as your scribe.)
Anyhow, once scribed I used a fine hacksaw to cut and limit the fiberglass dust.
Once cut, I bolted my two delete pieces together and laid them on a fiberglass mat, cut side down. under the mat is a plastic bag. Then I applied the resin/activator mix to the mat at shown in the pics. Just enough to create the flat area I need to create my delete.
After it hardens, remove the plastic bag and trim the mat about an inch wider than the resin you applied.
Use the resin/activator stuff to glue the mat "fringe" to the inside of the delete housing, being sure to fill all the mesh, get it as airtight as you can. Let it harden.
I did some rough bondo work on top of the delete box (I am not all that worried about the best appearance, but If you put attention to this I am sure your results will be great).
Finally some paint, and I have my Delete box.
$13 for a fiberglass mat kit, and not too much bondo and paint. So lets call it $25 and I am good to go! Thanks to the DIYers out there who share their ideas! The concept was not mine but this was how I accomplished it.