Need heater box & advice - '81 K10 p/u w 350 & a/c

[Frankenstien]

Hey all ... I was hoping someone could offer me a little advice here ...

My newbie attempt at a heater core replacement job has gone awry ...

I was on the verge of getting the last heater box (through-bolt) nut completely off when it jammed up tight
(due to 31 years-worth of crud, and, my failure to be patient and first clean the exposed threads --> lower left through-bolt, viewed from engine-bay side of f/w)
and the unique-looking bolt-head/clip
(interference-fit? / stamped? together right on the heater box, or, are the bolt shanks square and fit in square holes molded into the box itself? --> lower right, viewed from interior side of f/w)
let go and started spinning internally.

My next trick was to set up a small hydraulic jack (inside the truck interior, in the passenger footwell) against the said bolt-head/clip in an attempt to hold it while I tried to work the backed-off (but jammed) nut back and forth on the stud ... after a liberal dousing of WD40 this time.

This did not work, and, the lower right (viewed from interior side of f/w) corner of the heater box broke and has nearly completely broken away from the rest of the heater box.

I will try to get a pair of vice grips on the exposed portion of said stud (between the nut and f/w) on the engine-bay side and see if I can hold it that way. The fact that I have a/c and its' proximity to the R inner fender makes getting my fairly large hands in there quite difficult.

By whatever means I finally get it apart, a few Q's occur to me.

Is the kind of box damage I have described repairable?

If so, what is the best alternative to the stock (unique GM design) bolt arrangement that was used? And, have I got them all? ... two on lower edge of box, one on upper edge and a large hex-head screw on the far R (interior side). I am also assuming I don't have to disturb the a/c shrouding on the engine-bay side.

If box is not repairable, I don't yet see any after-market heater boxes available new online with the usual vendors (LMC, Classic, RockAuto) ... my search here on the forum turned up 23 threads' worth of reading for 'heater box' (which I will get to shortly) ... meanwhile ... can anybody say whether these heater boxes are generally available here on the forum?

And, are there heater box part variants for trucks with or without a/c, having different motors, or, any model years within the '73-'87 model year range?

As always, any help offered will be greatly appreciated ... thanks

[boatpuller]

hey frankie..i know from my own battle with those bolts they are a pain in the a$$...from what i understand from your post i think that's all of them.you should be able to get that box and whatever else you need at a bone yard.i hated that ugly box so much when i started restoring mine that i splurged for vintage air and heat as i was kinda going the show truck route..i know that wasn't much help.but,i "feel your pain brother".anybody thats ever goofed with those bolts can relate.

[Frankenstien]

bump ...

[6772fan]

I always said that GM must set the heater core in the floor and build the truck around it. Anyway, I always remove the passenger side inner fender and you can then easily ensure you've got everything loose from the engine side. In terms of repairing what you have, it can be done, but I don't know that I would trust the repair over the long haul. Check the parts section or Craigslist for a local complete AC heater box replacement. I don't recall which years interchange, someone who does will chime it. Good luck.

[trout]

Originally Posted by 6772fan

I always said that GM must set the heater core in the floor and build the truck around it. Anyway, I always remove the passenger side inner fender and you can then easily ensure you've got everything loose from the engine side. In terms of repairing what you have, it can be done, but I don't know that I would trust the repair over the long haul. Check the parts section or Craigslist for a local complete AC heater box replacement. I don't recall which years interchange, someone who does will chime it. Good luck.

x2 and far as i know ive only taken 3 84 cabs apart and looks to be the same thats in the 78 been picked heavily and the 76 im redoing im planing on take the heat out and put in heat and air form the parts i got from the 84s

[Frankenstien]

6772fan & trout ... thanks for stepping up ... I never considered removing the inner fender ... my truck is all original and kinda' rusty as far as all those R inner fender fasteners are concerned ... I'd hate to have to wake that dog up ...
at this point, the odds of me finding the right heater box are looking kinda' slim (but I haven't tried Craigslist [locally] yet), so, when I do get the bugger out, I'll probably take it to International Plastics (Richmond, B.C.) here in Vancouver, Canada and see what they have to say - they've repaired RV water tanks & such for me in the past. FFF

[trout]

i would think 73-87 -91 would work long as its a square body