Raul
Here are some pics
I separated the blower from the exchanger (few screws) and used aluminum strips bent into brackets to mount to the 2x2 in a location that clears guages etc. making sure that the top face of both openings were on the same plane and that there is enough clearance below for the heater door to open. I then used cardboard to make the front and back plenum shape with flats on both ends to meet each unit and a curve that maximized the space between. Then just strips of cardboard to do the top and bottom pieces. Taped it up and checked for a good fit. I then used very thin aluminum sheet that is sold in rolls for body work (cuts like paper) to replicate the shape...this time leaving enough for a flange around each opening and tabs on the sides to joint the top and bottom. I the riveted it together and covered the seams in foil tape. I put weather stripping foam around the openings then sheet metal screwed the flanges down into it. I covered the defrost openings.
Dash looks odd here as I left extra covering on the top to ensure no gaps with body on.
[ July 09, 2004, 06:41 AM: Message edited by: Cwood ]