The main, right hand duct was a horrible design. Believe it or not, that was the nicest duct I have seen in a while. The factory molded in a half circle area on the front that employed two star washers and two long screws to retain it in place. But since it is internally unsupported and there is a 1/2" gap between the top and bottom, the moment the screws were tightened, it crushed and shattered the surrounding ABS plastic. Unless you can slide something inside that area and glue it in place to support the outer flange area, there is no way to fix the existing problem. I can't remember, but I may have done that with the duct on the black car.
The ducts don't seal well together to begin with since all the foam stick-on insulation long since turns to dust. Home Depot/Lowes sells really inexpensive stick-on door seal foam tape in various sizes that works well to reproduce the original duct-to-duct seals.
Even the SD I now have has cracks in that same mounting area, And I was the first person to ever remove it when I replaced the original heater core last Fall.
Last edited by njsteve; 03-02-2014 at 09:51 AM.
|