Removed AC, need to fill gaping hole...

[Maxhouse97]

Any ideas for how to fill this hole? It's the one to the right of the white cylinder (windshield washer pump). As you can see I filled the other hole with a piece of AL sheet metal, but this one is not flat/flush. It has a step to it that would required a shaped AL plate. Any ideas?

[Bob Kontak]

The tubs were not made with or without AC so there is a big honkin' rectangular hole under the plastic "baffle plate" on all of them. I looked up this part in the PET parts diagrams hoping to find a factory blanking plate to cover. No dice from a three minute check.

I bet you will get input from pre-SC owners that have no factory air.

[SpyderMike]

I am planning to duct fresh air to the center vents from there using a fan. Plenty of space on either side...you could sandwich two plates with a few bolts and no one would be the wiser.

[cmonref]

The tubs were not made with or without AC so there is a big honkin' rectangular hole under the plastic "baffle plate" on all of them. I looked up this part in the PET parts diagrams hoping to find a factory blanking plate to cover. No dice from a three minute check.

I bet you will get input from pre-SC owners that have no factory air.

It is apparent that they DID make "with" or "without" AC. My Euro 1980 911SC came without factory AC and does not have the holes in the front trunk for the condenser that the OP now desires to close off.

[merlinfe]

Use two pieces of thinner sheet aluminum. One on the front, one on the back. Use four bolts through the two pieces while sandwiching the chassis metal. You could even use black weather stripping to seal it up.

The thinner sheet aluminum should allow some play in the metal so you can shape it to the step.

-Steve

[GH85Carrera]

Originally Posted by cmonref

It is apparent that they DID make "with" or "without" AC. My Euro 1980 911SC came without factory AC and does not have the holes in the front trunk for the condenser that the OP now desires to close off.

The SC line indeed came without AC on some cars.

For the Carrera one of the upgrades was standard AC on all cars. Like the bigger brakes and a 3.2 engine. It was standard equipment.

[rattlsnak]

You can use one piece of tin like you did on the other place. Just pre drill 4-6 holes in the new piece and screw them in from one side to the other and it will form to the body. Doesnt have to be air tight, but i put some sealer around mine anyway.

[Ayles]

I tried the metal route but, ended up doing mine with a piece of plastic I cut to fit and glued in. No drilling and future removal will be easy.

[gomezoneill]

I wish someone could 3 d print these so they snap in and the same for the condenser hole. I just cut out a patch and mig weld them. Takes a long time PITA.

[911SauCy]

I took one of Mrs Saucy's baking sheets, traced, cut to fit, sanded, primed, painted, riveted in...good for another 39 years...

[Bob Kontak]

Originally Posted by cmonref

It is apparent that they DID make "with" or "without" AC. My Euro 1980 911SC came without factory AC and does not have the holes in the front trunk for the condenser that the OP now desires to close off.

Thanks for this info. I was wrong in my "certainty".

Appreciate the kind push back rather than a flame (which I deserved).

[Maxhouse97]

Ok I like the metal sandwich idea. Can do that now.

On the plastic, what type did you use?

[jchris]

I fit mine with cardboard to make a template. Then made a duplicate with aluminum. I just siliconed it in.
Don't make fun of my super dirty frunk!