Got Dash? 5/26 (lotsofpics)

I'd definitely use sound deadener for the firewall and the floor. I like using HushMat Silencer Megabond which is a memory foam that absorbs sound and heat. It doesn't give off that stinky tar smell during hot days like Dynamat and other brands do. I used the HushMat Ultra for my roof and its been 7 years now and its still holding after many hot summers. This stuff sticks incedibly well. http://www.hushmat.com/products.htm

 

 

a heater/defrost/vent setup (non a/c) from my Elite is going in.. I have no real need or desire for it. Just wasted space and weight for something I'd use less than 2 weeks out of the year.

Like an intercooler sprayer? I think you'd be fine with an aluminum radiator in the car.

lol. I'm in massachusetts.. It's 50 degrees out as I write this. I'll have maybe 2 weeks where it's 85 with 90 % humidity.. I can live with it for two weeks.

Reassembly begins. I got the non A/C box in the car. I had to grind a bit on that bracket to the side of the gas pedal (the pre 77 cars don't have that). I also had to cut the heater vent on the base to clear that bracket.. no biggie. The fun part was locating the 3 holes for the heater box bolts, AND the fan motor, AND the heater hoses.. somehow I managed to get all the holes cut, first shot.
Yes, that white panel is from my old washing machine.  That flat filler panel will be seamed and body color once all is said and done.


Now the fun part.. the drivers side vent. That involves cutting and welding this piece into my Cougar.

LOL. The glove box is the same piece

The cowl itself was in excellent shape, so I buzzed it with undercoating. As for the washing machine patch, I'll paint that when the time comes to paint the firewall. It's already powdercoated. hehe.

Around 6 PM last night, I almost quit, after breaking 2 sawzall blades... I forced myself to continue, and got the piece I need out of my Elite. The second pic shows the piece.. I POR 15'd it.. POR is great stuff, like you said. I did the frame on my Elite and the floors, etc.. before I gave that car the middle finger. You can see I had everything dynamatted and all.  

This little hole allows air to come through the cowl into the drivers vent on the dash. If you simply cut a hole, water would pour into the cabin when it rains, a la my Cavalier did when I first got it  :lol: . Hence, the bowl that Ford has. The third pic shows the neat little hole I cut into the Cougar, that I can weld this plate with the bowl-opening into.

Update 5/26

Doo de doo.. Continuing..
I picked up some "non" A/C controls.. which for the 77-79 are hard to find. You can see how rusty they are. Interesting that Ford went from metal to plastic housings in 77 for the HVAC controls (the metal units are 3x as heavy). (pictured are a/c and non a/c for a 77-79 and non a/c for a 72-76)

Of course, the controls were SEIZED solid. I stripped them down, removing the sliders, wiring, and hardware, and swapped the sliders from the 76 non a/c controls.

Incidentally, the 76 non a/c controls were a set I picked up NOS on eBay for $20, so I have new sliders, switches, and hardware.  Physically, they interchange.. go figure.

Some quick work with a paint pen and some cleaner made the 77-79 controls look perfect ( 77-79 on left, 72-76 on the right).. I think the 77-79 looks better.. hence, I used those.

 

Then, I installed them..

Voila.. the transformation from A/C to Non A/C is visually complete. Now it's just paint my steering column, reinstall the gauges, and go! On an unrelated note... I found that Fomoco used THREE styles of knobs on these sliders. Sheesh.

   Paul I sent you a PM let me know! Gary