[Boomyal]

Several years ago, my heater core started to spew coolant into the passenger footwell. I looped the heater hose and pulled out the heater plenum. I popped the rivets on the whole assembly and had all the rusty metal pieces powder painted. That's as far as I got. The pieces are still sitting in a box, in the trunk.

At the time, I looked into a 'rebuild' kit for the plenum. It seemed that the foam seals were real cheesey so I did not buy it.

Is anyone aware of a source for a high quality seal/gasket set for the heater plenum, maybe a link for one?

Also, I'm going to have to rivet this thing back together. Has anyone used black pop rivets?

[busybee1]

John,
I too had coolant all inside the car. When I restored my car I brazed enough copper tube to the heater core to extend through the fire wall so I could connect the water hose in the engine compartment instead of the cabin.
I believe all the Mustang parts people use the same suppliers. I highly recommend the following. I have always had good service and good pricing from them. I used their plenum kit & it worked OK for me. Even new the seals were nothing to brag about.
Mustangs Unlimited - The Premier Source for Mustang, Shelby and Cougar Parts and Accessories
At least order their catalog-- it is FREE.
Good luck with your car.
Harold

[Jay H 237]

Here's the link on my website with my heater box rebuild, heater_core_replacement

[Boomyal]

I like the idea of extending the heater core tubes so the hoses can be attached from the engine compartment. I guess this will allow the clamps to show whereas they would be inside the car, otherwise?

Will standard plumbing solder withstand the rigors of the engine environment or should I take the core to a radiator shop and have them do it. I don't know what compound they use to 'solder' up radiators and such.