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Removed the a/c and heater from my.66 Coronet and I'm trying to out how to cover the hole with the lip around it. I don't want to remove the lip and don't want to buy some machined piece. What are my options? Thanks.Stew
Make a piece of wood in the shape you need and then bust out the rubber mallet and form the aluminum around the wood. You might have to do a few before you get it right because working the aluminum too much will cause it to work harden and crack. When finished you can trim the perimeter with a dremel or other small cut off tool. The other option is to gut the original and have someone weld it up and then hide their sins.
I ended up going to Lowes and getting a stainless switch plate cover. Bolts go inside the hole and sandwiched with a plate on the inside so I didn't have to drill new holes. Looks kind of funky in stainless but once it's painted I think it will blend in well.