Heater Core-ectomy Gory Details Part 1

[mwoodland at Valicor.com]

Folks,
I'm on the road, and don't have access to the car for pictures. If anyone
can send me some digital photos of the heater box, in situ, from drivers
side, top, and passengers side, I will diagram the cut lines and email to
anyone that wants. I've had an offer to have them posted on quattro123.com,
where they can become public domain.
In the meantime, for those of you that don't have the time to wait, here are
the words.
To answer the question "Why destroy the integrity of the box to save a
couple hours of effort?".
1.	I didn't have access to those 'extra' couple of hours.
2.	RTV or Goop should take care of the 'integrity' issue.
For the purists with time on their hands, read no further, and I'm sorry for
the WOB.
If you don't have, or want to take the time, and could use some heat right
about now, read on.

Once again, I can't stress enough that the secret is a Japanese style
key-hole saw, that cuts on the pull stroke, keeping the saw in tension,
rather than compression. I had planned on using a hacksaw blade with a duct
tape 'handle', before I remembered the keyhole saw.

After removing the black plastic (POS) cover over the heater box assembly,
remove the wiper assembly (3 screws and one electrical plug). Hood removal
is optional, but would probably make life easier. I was hammered for time,
and left the hood on. Carefully pry off the cable that actuates the air
flaps (passenger side), and remove the clip that secures the cable to the
heater box.

I had already made a few cuts (hacksaw blade) years ago to R&R the blower
fan motor, so... make a cut, starting on the passenger side corner, forward
of the hold-down strap, across the top, to the center parting line of the
heater box. From the passenger side, continue this cut down the side and
forward to the opening (9:00 position) for the flex bellows that connects
the heater box to the A/C box (black) on the passenger side. Using the saw,
or a dremel w/small circular saw blade, cut the front of the box, as far
forward as possible, from the 3:00 position of the bellows connector
opening, to the parting line at the center of the heater box. After prying
off the metal clips clamping the two halves together, 1/2 of the top should
lift off, exposing the bellows connector. After removing the one Phillips
screw that attaches the bellows to the heater box, the bellows will rotate,
and lift up and out of the opening. Take your time, and try not to brutalize
things, as it's not as effortless as I've just described...