What to fill holes drilled in heater box

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340wedge

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I have a heater box that someone held together with screws instead of the clips that join the two halves. Does anyone know what I could use to fill the holes that would be a good fix? Thank you.
 
Yup. I rebuilt (2) Dodge truck heater boxes, ( both of mine are factory original "non AC" that I'm adding AC to, using donor parts off of factory ac equipped junkyard donors).
I used a 3rd factory AC box I had that was missing parts as a "parts donor" and filler material for one of the good ones I ended up with, I cut up the 3rd box that also had a huge hole in it/ besides what it was missing, and used that to fix a crack in one of the good boxes I have. I JB welded a piece of flat heater box case material over a crack from the inside of one of the units that became a "good" unit, crack was in an area that didn't interfere with the movement of any of the doors within the heater box. And won't be seen. I got parts from DMT and the only thing was that what they supply in the just is great they can't/ don't supply the foam on the blend door or the recirc door ("reg AC vs "MAX AC") for which I found some great substitute for by wading thru the huge selection of different foam materials listed in the McMaster Carr catalog. I don't remember now which particular material I went with but they sell it in 12x12 squares and some they have bigger sheets of, or in a roll depending on which foam it is.
 
I use JB Weld; the grey the 5 minute cure stuff for smaller places that do not need a lot of strength and the 24 hour stuff when more strength is needed. I use a combination of tape and plastic wrap to keep the glue from running away from where I want it to stay. For larger repairs, I use JB weld and some chopped fiberglass fibers.
 

Duroglas auto body waterproof filler.

It's green when cured, so will have to paint it when done.

Great product, shapes and sands to needed contours.

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☆☆☆☆☆
 
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