AC Box Rebuild-Missing Flapper Door

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1meanfish

1meanfish

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I'm in the process of rebuilding the factory Ac/Heater box in my 1967 Barracuda. I was almost done when I noticed that the interior door and lever on the exterior of the box that bolts to the door which the lower vacuum servo operates, is missing.

Any ideas on where I could get something like this? I guess I could try and fabricate one if all else fails, but wondering if anyone had any ideas who might have these parts? Obviously nothing on Ebay, and no one is going to make such a one off part.

Here are some picks of the what I'm talking about. As well as a pick of what one with the door and lever in place?

IMG_7812.jpeg


IMG_7820.jpeg


IMG_0290.jpeg


IMG_0291.png
 
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Oh, and that AC, heater blower switch. Where exactly does that go? I've searched all over the AC box and the only two holes that match up is where I have it in that picture, but don't know what would hit that switch there unless the lever on the missing box activates it somehow?
 
You talking about the door that directs air either to AC ducts OR directs air to floor/defrost? When I rebuilt my heat AC box on my '69 that door did not look like it could come out of metal housing as far as I could tell?
 
The little door that sends air up to the Defrost is intact and does not look like it can be removed. That one is operated by the vacuum on top of the AC box.

But this door is definitely gone? It looks like the door between the AC and heater box? I think it allows or stops air from going through the evaporator.
 
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Heater Treater makes doors/flappers for newer vehicles. They may have suggestions or sources for older parts. Shot in the dark.

Contact Us - HeaterTreater

HeaterTreater offers the ultimate solution to blend door repair. Fix your car's head and A/C in as little as an hour and save up to $1493 in replacement parts and labor costs!
heatertreater.net heatertreater.net
 
1meanfish said:
I've searched all over the AC box and the only two holes that match up is where I have it in that picture, but don't know what would hit that switch there unless the lever on the missing box activates it somehow?
Click to expand...
I think you are correct. I can get a photo if no one else comes through. It on a top shelf in the garage.
 
I believe Dana is correct. That "switch" i think goes closer to lower drivers side. I could be wrong tho. I belive it acts like a "thermostat"??
Not sure if you have installed the spring clips around the perimeter yet? Those things are DAMN TIGHT!!
Before we reinstalled ours i took some of the tension outta them. They will crack the 60 yr old casing very easily.
 

1meanfish said:
The little door that sends air up to the Defrost is intact and does not look like it can be removed. That one is operated by the vacuum on top of the AC box.

But this door is definitely gone? It looks like the door between the AC and heater box? I think it allows or stops air from going through the evaporator.
Click to expand...
Sounds like the door that sends air either through evaporator core OR sends air down to floor heat ducts. That door can't be removed unless one breaks the welds and separates the rod from the door. When I rebuilt my '69 I had to glue the new foam on each side of that door with door stuck in the housing.

If its like my '69 no one is going to remove that door without breaking welds between door and rod. Best bet is to find another housing that still has that door intact. Or fab up rectangular door, fab up rod, and weld 2 together inside housing.
 
4spdragtop said:
I believe Dana is correct. That "switch" i think goes closer to lower drivers side. I could be wrong tho. I belive it acts like a "thermostat"??
Not sure if you have installed the spring clips around the perimeter yet? Those things are DAMN TIGHT!!
Before we reinstalled ours i took some of the tension outta them. They will crack the 60 yr old casing very easily.
Click to expand...
Yes, the heater side of the unit is all together and ready to. No issues with that side.

You are correct, those clips were a little scary installing knowing that the box is old and brittle. What I did was use a pair of sheet metal vise grips to spread out the pressure and SLOWLY squeezed until the gap fully closed and new sealer put in the grooves had spread out. Then the clips when on pretty smoothly.
 
340sFastback said:
Sounds like the door that sends air either through evaporator core OR sends air down to floor heat ducts. That door can't be removed unless one breaks the welds and separates the rod from the door. When I rebuilt my '69 I had to glue the new foam on each side of that door with door stuck in the housing.

If its like my '69 no one is going to remove that door without breaking welds between door and rod. Best bet is to find another housing that still has that door intact. Or fab up rectangular door, fab up rod, and weld 2 together inside housing.
Click to expand...
Yep, that is the one. But mine is definitely gone. The box has not been taken apart.

In the ‘67, it looks like there are two holes for the rod that holds it in place. I guess it can be removed without tearing the actual box apart by pushing the door up on one side, then pulling one side of the rod out of one of the holes?

I might have to try and fabricate something up? Another trick will be getting a lever, the part that bolts door on the outside that the vacuum actuator connect to.
 
Here is a picture of my box when I took it out of my '69 a year or so back to rebuild it. The door has little clearance side-to-side. When I had mine apart I wanted to take that door out because foam must be glued to each side of that door. Plus I wanted to paint that door. However there was no way it would come out without either bending housing OR breaking the welds between the door and the rod. It appears the rod was put into housing then the door was welded to the rod.

AC Door.jpg


AC Box Sanded.jpg
 
340sFastback said:
The Factory Service Manual refers to it as an "Air Conditioning Door"

View attachment 1716358905

View attachment 1716358906
Click to expand...
That’s definitely the door that’s missing. Not sure how they got it out, but the rest of the box looks untouched as far as the welds. Maybe they cut the end of the rod off or something then pulled it out?

The big question now is how do I get it working properly again? I guess I have to try and fabricate something, which would include the lever on the outside. Try to find another housing that still has the door intact, or go aftermarket?
 
I took one for the team 40 deg in the garage 30 outside.

Climb on a ladder

This is a 67 dart AC

PXL_20250128_022109444.jpg
PXL_20250128_022123212.jpg
 
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