Basic Heater Box Rebuild 72 Charger

I bought the Detroit Muscle Technology rebuild kit for my no AC heater box. I've glued on the obvious door foam pieces but I've got three pieces left over and one door. Anyone know where these pieces go?

I've also got these two pieces of cardboard which I can't place -



The round piece may be under the blower motor. I haven't pulled the squirrel cage fan to see for fear of breaking it. The fan is in good condition but after all it's 45 year old plastic, I don't want to push my luck.

Yes - the round gasket fits over the 2 studs on the blower motor.

The nylon on the squirrel cage is pretty robust; I've never seen one crumble.

The black cardboard is a deflector for the footwell heat -- it will clip onto the base of the heater box. Perhaps someone else has pics.

I've tried removing the squirrel cage fan. I took the metal clip off of it and it was still solidly on the motor shaft. I stopped there because I don't know what's holding it on - did it glue itself to the motor shaft with time or is there another fastener?

I would guess the original cardboard gasket is still good but I'd go ahead and replace it if I could get the fan off.

I'd love to get more info on the footwell deflector. I believe I've got the original somewhere but I can't recall it being on the heater box. It must have been, but I first took the box apart over ten years ago, and apparently I've forgotten the original disassembly.

Try heating up the cage to shaft boss area with a heat gun/hair dryer.

I've figured out the big cardboard piece. I wonder why they used cardboard instead of molding closings into the box? Bizarre.

The old blower gasket looks fine, so I'm leaving it.

The parts list say the two solid foam pieces are for the "floor heat/defrost door," which must be the door I have pictured with them. The parts list doesn't show the foam piece with the hole cut out. I'm still not sure what's going on here. I ended up putting the piece with the hole on the inside of the floor heat/defrost door, that has the big piece sticking out, and a solid piece of foam on the other side (before I found my instructions, which had been conveniently misplaced for this step). The solid foam pieces look like they are much too wide for the hole they're supposed to cover. They're supposed to be a little too wide to make a good seal, but it looks like they are far far too wide.

Here's another piece I'm not sure about, the "Driver's side fresh air vent to cowl seal-"



Maybe it will make more sense later. Right now I can't think of any spot where it looks like this would go, other than around the blower motor. The name implies it goes elsewhere and it also doesn't fit in any spot around the blower motor, although it looks like it would. So I'm at a loss.





It looks like a better fit in these pics than it actually is. I'm sure this is wrong.

Turns out it does go on the driver's side fresh air vent, as the name suggests. I'm surprised this was included in a heater box rebuild kit.