Firewall Conversion A/C Car To Non A/C

[69DodgeCharger]

Here is something that has my project pretty much stalled out. My car is an original A/C equipped car. Since I don't have any of the A/C components, interior or underhood I am wanting to convert it to a non A/C car. I do have a correct working heater box and heater controls from a parted 69. My body man is talking about grafting a portion of a firewall from a parted 68 into my 69. Getting him to actually get around and do could take months...or even longer. He works very slowly. Even money will not motivate him.

Has anybody else ever done this type of conversion? If so what did you do to get it done? Working heat and defrost is a must for me as I live in mid/northern Michigan. I am also wanting to have a factory appearance underhood. Originality and resale are not an issue here. Lets here your thoughts on this.

[Charger_Fan]

You may be able to make (or have someone make) some block-off plates to cover the holes.
This is a Dart that the owner eliminated the heater altogether, but the same principle would work. If it's done right, it wouldn't look too bad.

[A383Wing]

I went the other way on 1 of my cars....went from non-a/c to factory a/c......what a job cutting the firewall to fit...

Won't do it again...

Bryan 

[Brock Samson]

 that's an "interesting" place to put the coil..

[PocketThunder]

I have not done this but i gotta ask...... why wouldnt you want A/C for those HUMID summers in the midwest!!

[BigBlockSam]

that's a nice looking engine bay. Rene   

[69DodgeCharger]

Pocket,

I can deal with the heat and humidity, just roll the windows down. But I can't deal with cold and "fogged" over windows. Driving season starts in April and can run til November up here, by then it's pretty chilly usually. Plus I can't handle the cost, hassle and cluttered underhood appearance of an A/C car. Apparently this is not done very often. I thought somebody else might have done this already?

[Iceyone]

I'd say cut some sheet metal to fit the holes, weld it, smooth the welds, use filler if needed, prep and paint it. Doesn't seem like that big of deal to me.

[Drop Top]

If you have the fire wall pieces es to do the job with. Then that would be the best looking way to go. It will take a bit of work but when done will look like a factory firewall. If you make plates for the holes it will cheapen the looks of the car. Thats just my opinion.

[69DodgeCharger]

I have a complete firewall to work with....getting somebody with a lot more experience than me to graft it in will be the "issue" As far as the metal block off plates I have seen a number of cars with them and they look "cheap" under the hood, not to mention not having working heat and defrost capabilities....A must up here!

[B Bodyman]

I'm doing the same job for a customer at the moment,I'm using a '67 belvedere non a/c parts car for a donor,and the heater box from a '68 roadrunner.

[B Bodyman]

here's some pics,of what you need to cover up,first is the oem 68 charger with a/c firewall.

[B Bodyman]

any 66-70 B Body non a/c firewall has the same 6 stamping ridges,for strength,w/out all the holes,and can be easily cut out,and butt welded into the car,polish off the welds,a little everglass and prime.here's the donor panel,gotta' get the /6 outta' the way to make thing's easier.

[69DodgeCharger]

B Bodyman,

Thanks for the pics. Where are you planning on making your cuts? My body guy wanted to "overlap" the patch. I like the buttweld plan better. Is there any difference in the mounting holes for the heater box?, or is it just a simple matter of filling the old ones and drilling some new ones. I, and probably a few other people would like to see some more pics of this job as it progresses. Surely there must be other people who would like to do the same...Thanks for the info!

[Nacho-RT74]

I just would go with an overlap cover bolting it on same original holes...easier to got back to A/C system again if you want in a future. also cheaper.

[B Bodyman]

 ,I will butt weld a new section in,that 68 charger is actually member Firefighter 3931's car,I had planned to use that belvedere parts car in my yard,,but he dropped off a donor section,I'll have to measure up that donor piece,and make sure it was cut large enough,no worry about this car going back to a/c if you've seen the mill Ron has built for this car,and it's future plans don't have a/c in the cards. So,we want a permanent heater box only, I'll be working on that car this week,so,I'll keep a few pics for ya bud !

[69DodgeCharger]

Thanks B,

Same story here, don't want A/C. Don't need it. This car will never be going back to it...at least not under my ownership! Looking forward to those pics when you get a chance.

[B Bodyman]

I haven't forgot about you 69,I've finally got all the media blasting done,somebody stored the donor panel in some kind of cosmoline,and it's a bear getting it off,but I'll post pics soon...

[69DodgeCharger]

Thanks B,

I haven't had time to do anything with mine anyways, I just bought out a guys whole stash of cars and parts. That's been keeping me busy for the past week and half. But I am still looking forward to those pics!

[rebby]

I'd say cut some sheet metal to fit the holes, weld it, smooth the welds, use filler if needed, prep and paint it. Doesn't seem like that big of deal to me.

If that is a look that is alright with you, it is pretty easy 

http://charger.rebby.com/exterior.php?subpage=body&detail=june2005&item=3049
http://charger.rebby.com/exterior.php?subpage=body&detail=june2005&item=3048
http://charger.rebby.com/exterior.php?subpage=body&detail=july2005&item=3269
http://charger.rebby.com/exterior.php?subpage=body&detail=aug2005&item=3434
http://charger.rebby.com/exterior.php?subpage=body&detail=aug2005&item=3464

From my July 15^th log entry:

...We're going to smooth out the firewall too. I plan on using bulkhead connectors to pass through the firewall so this will clean things up quite a bit. We're doing this with a welded flush cover rather than cutting anything out and butt welding the metal so the option to return the firewall to stock will always be there. Before final welding, we'll seal things up so we don't get any moisture back there that could lead to rusting anytime in the future.

This is a work in progress. If you're interested in seeing how it turns out, keep an eye out here -> http://charger.rebby.com/exterior.php?subpage=body#current

[B Bodyman]

69er.,I had some time today to drag the donor car down from the compound to the shop,I removed the heater box and cut out a generous panel,,

[B Bodyman]

and a little quick grinding on the inner fender side,to get the fit right against the seams,it's basically in place,,I have it bolted temporariy,with the self tapping   bolts from the voltage regulator and ballast resistor,which holds it exactly where it needs to be,,,,I'll trim it a little more,around the hump and wiper motor area,then sandblast it,,and cut it in,and weld it,,everything lines up fine,one heater hose hole is already ok,I'll have to cut the inner one out. At this point a guy could just weld it into place and drill out 1 hole for the inner heater hose,then grind it all down and lay some everglass on the beads to hide it,,or he could spend the extra time and trace it out and butt weld it into place,,