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Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #746901 April 02nd 2019 12:59 pm
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Doing some more research on the topic, I can't find much of any info about sealing a HVAC box to the firewall. It seems that most applications would call for a foam/rubber gasket material like what I linked below. It would be cut to shape.

https://www.ebay.com/itm/Evaporator...1655075?_trksid=p2385738.m4383.l4275.c10


The other thing that seems to be highly recommended is 3M Strip Calk. That seems to be about the best option so far.

Not sure which direction to go, or if I should use both...I absolutely do not want rain leaks lol

Last edited by tuner4life; April 02nd 2019 2:35 pm.

[Linked Image]
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Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #746921 April 03rd 2019 7:54 am
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Finally got done with the sound deadening and foam. My arms are jello. I used Noico products and am very impressed with the results. There is a HUGE reduction in the resonance, boomyness, and echo effect inside the van. I haven't driven it yet, but just by tapping on the panels from the outside the result is dramatic. The doors also close much quieter

First picture is with the mat only, the second picture is with the foam installed over it.


[Linked Image]
[Linked Image]


[Linked Image]
Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #746922 April 03rd 2019 9:46 am
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Originally Posted by tuner4life
Finally got done with the sound deadening and foam. My arms are jello.
laugh I'll bet.

Looks nice. Very nice!

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #746986 April 04th 2019 10:07 am
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Butyl tape might be a good inexpensive fix for the Hvac seal. It’s flexible and won’t dry or crack.

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #747206 April 10th 2019 8:46 am
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Alright, I took my time and over the last few days I pulled the HVAC box out, then I took a wire wheel to the firewall where it mounts and got rid of all the old sealer and crud that had been built up. I repainted the area matte black to match the rest of the bay. Then I went through the HVAC system. I replaced the defective heater core, A/C evaporator, Accumulator, and orifice tube and all related seals. (All under warranty). I also warrantied the compressor because the clutch bearing was making noise. Then I put all the pieces back together and used 3M strip caulk to seal every possible leak area. I also replaced the foam between the heater box and the interior side of the firewall with new closed cell sealing foam. Then for the A/C box on the front side, I used generous amounts of 3M strip caulk and thoroughly sealed the entire assembly together against the firewall. Rain should never leak in that area again!

All apart and the firewall restored:

[Linked Image]


And back together:


[Linked Image]

Heater box partially re-installed:

[Linked Image]





My wife has been working on the upholstery while I've been dealing with the HVAC. She is still working on patterns and pieces so nothing too exciting yet, but she did finish these panels that will be part of the rear bench. I'm getting excited for how this will turn out!


Don't mind the marks, that's just excess marking chalk that needs to be cleaned off:

[Linked Image]

[Linked Image]



I'm trying to work on the headliner now.. I wish I could flip the van over and work on it upside down lol. 4 friends had a hard time holding the 12ft long panel in place to try to get it trimmed correctly!


[Linked Image]
Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #747209 April 10th 2019 11:16 am
Joined: Aug 2001
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Wow, very nice work! It will look and work great when you get it finished.


Windows- they're what make a van worth owning!
Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #747216 April 10th 2019 6:13 pm
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Wow can't wait to see the outcome

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #747232 April 10th 2019 9:46 pm
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Damn, that's some quality upholstery!


If it's broken- I'll fix it! If it's not- I'll break it to figure it out how it works so I can fix it.
Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread
tuner4life #747345 April 15th 2019 8:38 am
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Worked on the headliner a bunch this weekend.. Got several cool ideas for it which I will detail once it's done and actually works like it's supposed to.. Also got the rear door panels cut and got riv-nuts installed in the doors to mount them. I am going to try to find some shallow compartments with doors that can flush mount in the back doors. Not having much luck yet.

Also, last night it was raining a bit so I rolled it partially outside to see if my heater box refresh/reseal worked.. The good news is that I did not see any leakage from the heater box.. The bad news is that there was still water on the floor. This time I was seeing the water right in the area indicated below:

I checked the windshield seal and that is bone dry, the HVAC box also seems to be sealing up fine. At this point, I suspect the fresh/recirc blend door housing that is mounted into the kick panel.. I'm going to pull that out and reseal it and see if that gets me anywhere.

It's supposed to rain more this week and I fully plan on camping out inside of the van with flashlights until I am confident that there is ZERO water coming inside.. I'm not sure why this is so difficult. Does everyone's Chevy leak this much?? I just want to install my flooring ugh..


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