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you will need to remove the whole dash assembly. and while your at it replace the evaporator as well. your description deff sounds like the heater core

I thought there were thicker gaskets that could be used but probably not the best way to go

talk to the machinist and explain what you know as to the motor and what is going on. find out from him what he recomends you to do and or what to bring to him. that would probably be the best thing for you to do at this point.

like he said