Heater Box Swap

Here is the main reason i decided to pull it all out and replace and clean up the dash. the dealer ac was poorly installed. it removed moun… Owner This is the front of the dealer ac duct work. they hacked the dash bad to fit this in. this bronco only had heat no ac from ford. Owner Here is another view. they did not run ducts over to the driver side they added vents to the dash and blew cold air thru the dash. More qua… Owner Look at the wiring mess on the drivers side. this is the AC power and contol wires for the second fan and compressor and other AC related s… Owner another view of behind the dash. no vents to the drivers side. Owner This opn hole in the ac unit blew thru the dash to the drivers side of the cab. there was no duct work whan i got it ans the dirt showed it… Owner from the drivers seat you see these vents and the air came thru. not alot of it but it did move some air. Owner here are the vents on the back side of the dash. this was all there was. no duct work. Owner you can see there are holes for the ducts to connect to just no ducts. Owner After removing the dealer added AC this left a huge hole in the dash. most of the bracing was destroyed or cut out. the dash front was hack… Owner This is the dealer added AC system. it weighs 30 pounds no gas in it. Owner This is the dealer added ac condenser and blower motor.It did not work when i got the bronco so out it came and in the trash. Owner This is the top and front of the dealer add on AC. you can see where the vents connect. Owner Here is the connection that failed. They put a iron pipe inside the hose and it rusted away. the hose was loose and leaked. this goes to th… Owner This is the old AC compressor. i removed it to clean up the engine compartment. it was dead anyway. Owner This is the pile of wires i got to remove from the dealer added ac unit. this was a fire waiting to start on me. Owner well score from the junk yard. this is upside down but it is the missing duct works. Owner here is the new drivers side dash vent duct system. it goes behind the dash. Owner Here is is cleaned and installed. it was a small pain to get in the right spot but once in it fit like it should have from Ford. Owner Here is the pass side vent on the drivers panel. The dash got beatup bad. i been fixing as i go along. when i fist drove this truck the das… Owner To fix the dash i used thisscrap metal i had sitting in the shop. (It from a file cabinet) i made a sandwhich and riveted it to front and b… Owner After cutting and bending and removing sharpe edges and prime and paint here are the patch clips. Owner Here it the top center dash mount (you can see it in the top middle. i sandwhiched the dash inside the patch clips. i then used rivets to h… Owner Here is the patch all riveted in place. this patch sits under the top dash so it will not be seen when the dash is reinstalled. Owner Here is the driver side of the drivers panel installed. Owner Here it is almost all back together and looking good. Owner here is the drivers side vent system completed. you can see the connection tube in the hole in the dash. Owner While i was at the yard i got the other side duct works . this connects to the drivers side vents and the heater / AC box. Owner Here is the heater box side and connection seal. I washed out the ducts real good and then installed them. Owner This is the new pass side duct work. it connect the driver side duct work the heaterbox. Owner Since they hacked the dash support system i had to make a new support mount. This holds the far right side of the pass side duct work. Owner After removing the old heater box this is what the inside looked like. Owner This is the engine side of the firewall. Owner This is the stock 1983 heater / vent air box. the left is under the hood and the right is the part that goes in the dash inside the cab. Owner Here is the old heat/vent box. the heater core is under the hood not under the dash. the Blend door is in the center. Owner Here is the top view of the old heater box Owner Here it the firewall side of the heaterbox. the left side is here the leaves like to pile up and behind the blend door. I had a ton of leav… Owner This is my stock air distribution system that goes under the dash. Owner This is the under the dash connection to the defrost ducts. Owner here is the top view of the under the hood stock heat system. you can see the heater core connections on the right side. this is now off to… Owner Here is a view of how the old system goes together. the only thing missing is the fire wall in the middle. Owner This is the other side of the old heater box. Owner The 87 up diverter box has a door that send defrost air to the side windows. My 1983 does not have this option so i just glued the a block… Owner I drilled a hole thru the floor board for the condisation drain. you can see the line in red. You can see the new recirculation door i had… Owner The 87-up uses a recycle and fresh air option. i had to cut an extra hole in the fire wall for the recycle door. this is worth the work. Owner This on the top of the airbox and controls the Hot / Cold air selection Owner this changed the air direction from floor to defrost. this is all cable on 87/88 boxes and 89 up used vaccum pots to open and close the doo… Owner Here is the footwell or floor air port. Owner Here is the heaterbox. the connection end of the heater core can be seen at the top center. Owner here another view of the under the hood ac/heaterbox. Owner Here are the new heater hoses. and the new 1987 heaterbox. Owner Here is the connections on the front of the motor. Owner Here is the connection to the heater core. Owner