I ripped out the AC box on the firewall to free up some room. I couldn't believe how much extra room there was. I got a hold of a non AC heater box with new motor from a 1978 full size chevy pick up. It hangs perfect on the fire wall but is not long enough to stretch over the inlet to the heater core.

So I am going to cut the pickup box in half and lengthen it. It will look nice and be a very cheap alternative to finding a non AC box for a third gen.

I will post pics for anyone interested when it is completed.

I am starting the project today, so any comments from anyone with nowledge to make this project easier, or just general ideas please post.

Obviously thios is not what you would want to do if you are into originality.

 

I modified the stock one. I removed the top part of the evaporator box (the part that attaches with self-tappers), then cut the front of the main box off. Had a .050" aluminum plate made to bolt where the top screwed on and sealed the front with silicone inside. Got pics if youre interested. Looks pretty clean.

 

Sure post a pic. You get enough room this way to change the back plug on the pass side?

Sounds a lot easier than what I did yesterday.

I cut the truck's heater box in half, got some aluminum sheet metal and cut and formed the aluminum sheet to fit inside between the two pieces. Then I riveted it together and epoxied the back side of the rivets to prvent them from pulling through the aluminum sheet. It worked very well, and once I paint it black, and get it sealed up, it should not attract any attention.

 

i couldnt afford a AC delete box in high school.
first i took the top off the AC box and used sheetmetal.. it helped, but wasnt pretty.

then i cut the box apart just where the blower motor exit is. so all i had was the blower circle with a exit.
i then made the basic shape i wanted with cardboard.
then, when i was happy with the shape, i got some fiberglass and layed the glass over the cardboard....

made a nice, cheap AC box... i got the glass from a friend for free, but its less then $20 if you had to buy everything.

 

I thought about doing somthing similar too. But I busted up the heater box when I removed it and it broke the circle at the discharge end. I already had the truck heater box and I wanted to use steel. But I wish I had been more carefull when removing it so I could use it to make a heater box if I needed to.

 

I just cut off the box where it then evap used to be and bent a piece of galvanized metal and zip screwed it in, Doesnt look half bad...Plenty of clearance...You can almost see it in the pic on this site... Click Here

 

Sorry no pics of it on the car yet.

 

thanks formularpm, please post pics when you get it on the car