And today's challenge: refoam the heater box!
Okay, this was more the other part of the weekend, but things went so sideways I was not able to actually start cutting out the new foam bits until today. Initially I enjoyed how easily the dash moves out of the way and the hater box drops out but as soon as the core was removed it was apparent that small leaks were developing and that it might be a better idea to just replace the core now instead of a few years down the line. My options were one that Saturday afternoon locally for $170, or one from Rock Auto next Monday for $60 shipped. I chose the latter, so the car is all levels of dismantled as I wait for the core to arrive.
While I was doing that I decided to run a fluid check and found that there was fluid layering in the brake reservoir. I think what happened was that while the lid and the mechanics book says to use DOT3, at some point the car had its brake system flushed and refilled with DOT5. So when the car had the brakes done during the rear diff rebuild they topped it up as per book spec and it was just floating on the top layer.
With the system now contaminated (which is VERY bad in this case as it can destroy everything) I had to pump out the reservoir (my hand vacuum pump comes with a nice kit for this so), fill it with new DOT3 and then bleed any remaining DOT 5 out of the master cylinder, lines and brake cylinders by bleeding each wheel and topping up the reservoir as new fluid was pumped in.
