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Heater core removal and replacement......without removing dash or A/C

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Ok folks...here's where I'm at. Parts finally came back in and I'm (well I thought I was) ready to finish this thing up and get it back on the road, but I've got a small issue. Check out the pics and let me know what you think. The second photo is where I'm having a problem. The place where the blower motor came from said that this blower motor is to fit this year, make and model of the Scrambler; but the motor is 1" larger than the factory one. I got it all back together and now I need to make a larger hole.

Any suggestions on making the hole larger? I was thinking hole bit because I don't have a dye grinder.
 
What part number did they give you for the motor?
For the hole... do you have a drill with a grinding wheel... rotary file... maybe a Dremel with cutting bit?
 
Also, some motors come with a removable heat sink that is kind of a metal ring that goes around the motor housing. Make sure you don't have one on your motor or you'll be making a hole larger than you need.
 
AfghanaScram said:




Any suggestions on making the hole larger? I was thinking hole bit because I don't have a dye grinder.
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Once you determine the proper size hole you need, simply mount a piece of sacrificial material (IE wood, metal, etc.) with existing holes in the firewall so it passes across the center point of the desired location of the hole.
Mark your center point for your pilot bit and drill the firewall from the opposite side of the mounted material. This will center the hole saw and keep the bit from "walking"
HTH
 
Spieg said:
Also, some motors come with a removable heat sink that is kind of a metal ring that goes around the motor housing. Make sure you don't have one on your motor or you'll be making a hole larger than you need.
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X2 on this. Mine didn't look like it would come off, but with a little "persuasion" it did slide off. I scuffed mine up and used a little of the Rustoleum Hammered it looks real nice.

Also, I think you had fun with grounds in a previous post. The motor grounds thru the screws that attach to the body, so if you want to upgrade/improve you scratch the paint off and attach a dedicated ground so it doesn't bite you down the road.
 
AfghanaScram said:
DISCLAIMER: Yes I know that there's a million of threads similar to this one but I wanted to include one of my own. Mainly just to up my stats and so I could clear up some memory on my phone.​

Q: Why are you changing the heater core?
A: Because it's leaking.
Q: But a heater in Texas?
A: It does get cold here and yes I know that it'll probably be 98 degrees out tomorrow with 110% humidity and this heater won't get turned on for another eight months.
Q: What's next on the list?
A: FLUX CAPACITOR naturally
​















NOW TIME FOR CHOW...GOING TO REPLACE IT WITH NEW CORE AFTERWARDS. STAY TUNED!​
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Where did you get the heater core? I need to do the same thing. I'm in NorCal and it does get cold as hell here.
 
CactusBif said:
Where did you get the heater core? I need to do the same thing. I'm in NorCal and it does get cold as hell here.
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If you have the original heater core, I would suggest taking it to a radiator shop to have it rebuilt. The old originals are far superior to the new ones that you can buy. Just my opinion
 
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