The thread earlier today about removing blades from the fan reminded me that I hadn't posted pics of my worked over fan housing. Instead of just blocking off the two outlets that run to the heater boxes, I went the next step.
I took some 1/8" aluminum sheet and cut out covers or plugs to cover the outlets on the INSIDE.
I was able to shape (cut, file, grind, bend) the aluminum to fit tight in the opening. Than I used KB Weld (hey, it is still holding after 2 years) to bond the pieces in place. Than I used bondo (like I said, it's still in place) to fill and shape it up real pretty.
I also sanded the whole thing and filled some holes to clean up the air flow. It has to be an improvement over the stock set-up. Simple and cheap too.
Paul