Finally got ready to reinstall the lower heater box/fan (after a through cleaning). Two drivers side clips...no probs. 2 passenger side clips....no nice little "snap". Squirmed my way under the dash frame (dash is out, replacement softie is waiting in the basement), and it appears that the two upper box "ears" which will hold the top of the spring clips have been broken off (by me or the PO, hard to know).

So....looking to find a replacement upper box, but I'm willing to entertain ideas on fabbing a fix to this one. My heater core shows no sign of leaks, and the cooling system was flushed out by the PO's mechanic before I bought it. Is it better to remove the heater core (and drain the system) if I install a "new" upper heater box? No huge deal if I have to drain it....I have to replace the radiator switch anyway.

Anyone have an upper box assembly with good "ears", give me a shout!

Thanks. Otherwise, the rebuild progresses slowly but happily. Door cards are now finished with new grills and reinstalled chrome strips. Insulation is complete. Inner plastic panels are back in the car; drain hoses and top frame go back on sometime soon. Vic's Upholstery finished the new boot, and it's gorgeous! And Steve, those tail lights shined up very nicely! Thanks!

Neil

Problem solved, thanks to "juvius" (Thanks, Steve!!).

Neil