This is a nasty job, since old heater boxes are generally full of 30 years of dust and insects... I thought I was refurbishing this box to sell, so I did an extra phenom job of it. Lot's of people on the forums complain about it, but it is an easy job once you commit to it. :) All new grommets, new weatherstripping to seal the ducts, all apart and cleaned.
Cracking it open... oh, good. No dead rats.
Here's all of the old gunk I cleaned out.
Clean, and coming back together!
Crack repair - first epoxy, then a riveted piece of aluminum to make sure it doesn't spread.
