Rebuiding Inside-out Options

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Now the left side. First I modified the horizontal duct so it will insert into the exchanger outlet.

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Flap valve modified by rounding the lower corners.

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Ducts from the blower housing to the exchanger, and the vertical tube up through the sheet metal.

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Upper hole elongated, just like the right side.

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Horizontal duct forced into place. Now I just need the left side control box.

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Yesterday, the postman delivered another NOS heat control box.

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In case I was not sure which side?

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So that's where I put it. Upside down?

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I need a few more little parts to finish the heat system, so I played with some more stuff that got delivered recently.

Since I need to replace the PCV valve with an open fitting, I tried to find something that fits the holes (outer and inner) in the stock oil breather. It took about 4 tries, but I finally got a fitting (1.2 inch barb and 14x1.5 threads) in aluminum from Racetronix, and a 14x1.5 brass nut from Belmetric.

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It fits just right, with a dab of aviation sealant.

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Breather re-installed and the vent hoses all connected for real. We will see if this vent scheme works once the car is on the road.

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With a bit more time to play, I got down the rear valance. It still looks a bit lumpy but I figure it will not be too visible, and I would rather have the durability of powder coating--which means no filler (and means my limited metal forming skills can't be hidden).

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If you recall from 2 years ago, I had to weld in a patch to repair a very home-made PO hole on the right side for his custom dual exhaust. This view is the inside--the outside is not perfect but better.

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To install the valence I removed the bumper. No big deal, except...

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On both license plate lights, the ground wire terminals were broken. Time to re-do these before the bumper can go back on.

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I did get the valence mounted, with a little bit of persuasion since the curve of the restored rear panel does not quite match the valence.

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Clearance to the tail pipe is a bit less than 1/4 inch. I want to see if I can enlarge this.

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I replaced the ground wire terminals, and stripped back some of the heat-shrink tubing I installed last year so the wires can bend more easily. And then a quick check of the lights--they work!

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With the bumper back on the rear end is complete.

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I finally got my replacement for the throttle position sensor, from Summit Racing. This is a Ford sensor with a Delphi (GM) plug connector--apparently a relatively common custom EFI part. But the lead positions are not the same as what I had, so I switched them.