Thought I would put up some pictures to illustrate what I've been babbling about on and off for months. I'd managed to give some people the impression that in eliminating the A/C stuff on the wagon I had also removed the interior heater plenum and left it off, but that is not the case. The remnants of the A/C condenser "suitcase" were cut off of the HVAC blower housing, and I whittled up this little custom duct out of 22-gauge steel. It appears my measurements weren't quite spot-on, but this is part of why I don't try to pass myself off as an ace fabricator. I used FCAW (can't yet afford a tube of MIG gas) to join the sides mechanically and then wrapped with "metal repair tape" from Lowe's to reduce leaks. Granted, there are still far more leaks at either end where I haven't yet sealed stuff up, but at least I have heat to go with the neatened engine bay, and I'm no longer dependent on my previous makeshift solution in the form of some dryer duct and expanding foam sealant.
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