Quote:
Originally Posted by njsteve
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.
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Yes, if they would have filled in the duct area where the screws go so you cannot compress it, they would not crack. That is where if someone would make a good repop'd duct that actually fits and lines up, then improve on the design and fill in that area. That would be awesome.