The heater flapper boxes on the older 911's will rust out over time and need replacing. This would not be a difficult project if it were not for the fact that the nuts are probably rusted onto the studs that attach to the frame of the car. In removing the rusted heater boxes I snapped off 5 of the 6 studs on the boxes.
I looked into the different ways to fix the studs, but with the engine in place the options are limited. I tried to remove the studs from the chassis, but they were too rusted for that. I settled on welding them into place by using tack welds on the exposed studs that were left. Now I guess my only worry is how to get them off in 25 years to replace them when they rust out again.
This is not the purists solution - it is the solution that works best for me. I can not justify spending more on removing and replacing the studs than the replacement cost of the heater boxes alone.
OK, enough of the justification of my actions. I went to Pelican Parts for the heater flapper boxes, control cable and ducting to tackle this job. The heater boxes I received were a better design than the existing ones so I was excited to get underway with this project and find out how well they would work.
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