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Blower box leaking again..

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Old May 10, 2011 | 10:46 PM
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Default Blower box leaking again..

I had this out and resealed with rtu ( bad choice I know) about 2 1/2 years ago. Noticed tonight it was leaking again. I have it out now and the box is in weird condition. The PO has cut a hole in the right hand drive fan location. I can't figure out why this was done. At the time I bonded a plastic lid over the area but now I'm not sure what to do. i sure don't want this thing leaking any time soon. Does anyone have one sitting around thats not been butchered? OR...How can I fix this one RIGHT?

The vac actuator arm is also broke off the door. I bonded this 2 1/2 years ago but it did not hold. Ideas on this repair???

Also the large rubber seal that goes between the box base and body is in BAD condition. I plan on resealing with 3M caulking strips. Should I just leave this seal off and triple up on the caulking??? I reused the seal and added RTU on both sides...but again that was a bad idea. Are the seals still available new?
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Old May 10, 2011 | 11:17 PM
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use 3 strips of 3M Caulk remove the old seal first.
Question why it there a hole in the other area of the blower box adjacent to the blower motor area??
if this is open then water can get in
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Old May 10, 2011 | 11:22 PM
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Dean, if it was mine I would use an aluminum angle for the broken arm mount point and an aluminum disc to seal up the hole the PO made. Use pop rivets to attach both pieces. On the aluminum disc I'd use some of the 3M caulk to seal the disc to the housing. That or get a used one, but then the arm mount point may just break in the future.
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Old May 11, 2011 | 02:45 AM
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Originally Posted by Jim M.
Dean, if it was mine I would use an aluminum angle for the broken arm mount point and an aluminum disc to seal up the hole the PO made. Use pop rivets to attach both pieces. On the aluminum disc I'd use some of the 3M caulk to seal the disc to the housing. That or get a used one, but then the arm mount point may just break in the future.
Excellent Jim...I even have some aluminum angle on hand.
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Old May 11, 2011 | 02:46 AM
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Originally Posted by Mrmerlin
use 3 strips of 3M Caulk remove the old seal first.
Question why it there a hole in the other area of the blower box adjacent to the blower motor area??
if this is open then water can get in
As I stated in the first entry...I have no idea why that hole is cut...but I have to close it.
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Old May 11, 2011 | 02:47 AM
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I guess I need to reseal the flap door while I'm at it. What would be good to use there?
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Old May 11, 2011 | 11:40 AM
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I would ask around and get a good used part here it already is starting to look like swiss cheese

Anyone have a good blower box for a 1980 928
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Old May 11, 2011 | 05:13 PM
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I would use foam weather strip for the flap door.
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Old May 12, 2011 | 12:25 AM
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Stan's right, that box has had too much surgery. Time for a replacement. Wish I had one to part with.
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Old May 12, 2011 | 02:01 AM
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I can't figure out WHY the other fan location was cut out? What was he thinking?
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