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OK - so I am moving onto the AC unit...I am wondering if there were plugs for the firewall where the heater-only box mounted. If so, where do you get them? If not, how did Ford seal the cabin?
Are you adding A/C? IIRC, the 4 holes in the firewall are meant to accomodate either configuration: with A/C or without. The 2 holes inboard/vertical are for the non A/C configuration (heater only). The 2 holes horizontal/adjacent to evaporator lines & expansion valve holes are for an A/C configuration.
As far as plugs for unused firewall holes i've used the rubber body plugs. Worked out fine.
And in some cases you need to massage the holes and file a bit to get them to fit, as when punched out they sometimes get a bit of a "neck" which makes it hard to install the plugs flush..
I will try to get a photo of my firewall and ID the holes. I have plugged the heater hose holes already. It is the 4 bolt holes that the heater fan motor bolts to (for non-AC cars) that I am trying to figure out how to seal.
Here is what mine looked like once I added factory A/C to my coupe. The holes to the right that now have plugs are where the heater core came through the firewall.
I will try to get a photo of my firewall and ID the holes. I have plugged the heater hose holes already. It is the 4 bolt holes that the heater fan motor bolts to (for non-AC cars) that I am trying to figure out how to seal.
Everyone! THANK YOU! Doug and Scott - thanks for the photos. I found out that I am a complete moron - for like the 100th time while trying to put this car back together (some places like the 5th time). I had only put the rubber seal up to the fire wall and did not check fit the metal plates. The metal plates definitely cover the holes I ASSUMED that because the rubber gasket didn't cover the holes that the metal plate wouldn't either. Thanks again for helping a moron with his project!