1966 A/C box repair

[Joseph U.]

Attached is a photo of the A/C box on my 66. As you can see there is a crack and a small piece missing. The missing pieces are where the screws are supposed to go to attach the distributer assembly. Any ideas on a fix that I can do without removing the box. I tried some plastic to fill in the defect (by gluing a support to the inside of the box with a second piece glued to that to build up the hole and make things flush - but I can't seem to get the epoxy to stick. I realize this area is hidden and not seen so aesthetics is not the issue - but functionality is so I would like to do something other that "duct tape".
Thanks,
Joe
AC box.jpg

[Scott M.]

Re: 1966 A/C box repair

That is basically the approach I took to fix that area on my box. Seems to be a common problem. I used some scrap fiberglass pieces and glued supports on the inside and then glued to the outside to make it flush again. What kind of epoxy are you using, as long as it is clean, sanded with something like 40 grit it should stick. I just used some left over Evercoat panel bonding adhesive, but something like JB Weld should certainly do the job.

[Joseph U.]

Re: 1966 A/C box repair

I am using JB Weld epoxy. It is possible that I did not roughen up the surface enough on a piece of plastic from an old plastic box, so I have tried again, If that does not work I will have to find a piece of fiberglass someplace and try that.
Thanks,
Joe
PS: that seems like a large distance from the box to the defroster vent to me but all the holes seem to line up. Should I use a little AC tape here? Also does anyone use AC tape at the connections between the large air hoses and the plastic parts? Can't see where it would hurt but what do I know, but this is not an area that is judged. (I have the clamps for the connection that is visible on the drivers side).
Joe

Joe

[Scott M.]

Re: 1966 A/C box repair

Joe, your problem is more likely the plastic you are trying to use. You are better off with a piece of fiberglass. If you can't find any, I'll send you a scrap piece.

[Joseph U.]

Re: 1966 A/C box repair

You are probably right Scott,
Hate to put you thru all that trouble.
Have any ideas where I might look - I tried Home Depot and the local Hobby shops but they really don't have anything that would work - everything just seems a little too brittle. I took this project from another and all the old parts were discarded by him a long time ago so no old parts to sacrifice. Any ideas would be appreciated.
Joe

[Jim S.]

Re: 1966 A/C box repair

Joe,

Don't get mad with what I am about to ask , but I thought it worth a try .

I too had my car handed to me as a unfinished project and I had the same exact issue . I decided to try all sorts of things to fill it in , when I decided to look at the attaching piece for fitment etc. . It was there that I found the broken off piece still attached to it with the screws still in place . So I unscrewed it from there and JB welded it in place .

So my question is : are you sure it is missing, and have you looked at the attaching piece for it .

I know it's like asking someone " Are you sure it's plugged in ?". but sometimes , thats not a bad question .

Jim

[Joseph U.]

Re: 1966 A/C box repair

Jim that is not a bad question,
But I have looked everywhere - in all of the many boxes of stuff that came with the car and unfortunately I could not find that little piece. There are also some brackets that are missing so it is possible that a box never came with the car. I plan to look one more time, you never know.
Joe

[Joseph U.]

Re: 1966 A/C box repair

I received some "fiberglass" from Scott - and I am ready for the repair. I have two choices: I can put a piece of fiberglass on the outside of the box and screw the "Y" piece to that or I can try to glue two pieces together and fill in the hole so to speak. Obviously the piece on the outside of the box would be easier and probably stronger. The only downside is that it would shift the "Y" piece approximately 1/8 closer to the back of the radio and 1/8 inch to the left (drivers side) - does anyone have a suggestion. Since the "Y" does not seem to attach to anything other than the side plates of the console - I am not sure that small shift would make any difference but would like to be sure before I "glue it down".
thanks,
Joe

[Claus S.]

Re: 1966 A/C box repair

Can you get hold of a broken box which you can use to cut out and shape a piece to look like the missing piece and after that have some to plastic weld in back in?

It is pretty common this days doing plastic welding since most cars have plastic bumpers so there are several shops that welds plastic around
They weld plastic using the same color as the part they weld so it wil hardly show at all

I cant see if the broken part is on the box itself or on one of the distributor boxes but if it is on the distributor boxes LIC sell all of the parts including the inner AC heather box

[Joseph U.]

Re: 1966 A/C box repair

I suppose I could do that but the box is already in and it was a B%$@^ to get in and I would rather not take it out again. I looked at my 67 which was restored before I got it and there is a fix on that with a piece of fiberglass just glued to the outside of the box and the "Y" screwed to that. Seems to work just fine but that is not an A/C car. So my choice is to glue a small piece to the inside of the box (without interfering with the baffle in there) and then glue a piece to that to fill in the hole - or to just glue a larger piece to the outside of the box. I think the larger piece would be stronger in the long run and this is not an area that is judged, so my only issue is the slight shift in the position of the "Y" piece that this would result in. I may be over thinking this - at least so far it doen't seem that the tolerances are that tight under there.
Joe