(Re-posted from an older thread)
Wow, just finished swapping out the heater core and evaporator, and then reinstalling the AC unit back into the car. Do not underestimate this job. It is long, requires coordination, and is very messy. Ridiculous amounts of "while you're in there" work await you. This includes replacing foam, repainting rusty flap doors, and adding new foam to the outside of the AC unit if you have an early car like me.
The materials I used were:
- http://www.homedepot.com/p/Armacell-...3#.Ulc7RFM0Bp4 for replacing the foam on the various vacuum-actuated flaps
- http://www.homedepot.com/p/Frost-Kin...3#.Ulc8JFM0Bp4 - for adhering to the outside of the AC unit box
- 3M Strip Calk (yes it's spelled that way); available at NAPA auto parts, for sealing the AC unit box itself.
- And some Frost King 1-1/2" wide x 1/2" self-stick foam - for adding foam around the evaporator unit.