CJ-5 Heater Fan Upgrade Questions
 

There were a number of posts and website reviews on upgrading the heater fan
blower motor for the older vintage cj-5 Jeeps. My Jeep is a 1980 CJ-5.

I have read all the posts that I can find on this, and I would like to
summarize some questions that still remain for me as I prepare to assist my
mechanic for getting ready to do this for me.


1. Motor model. I note that the web article on Off-Road.com says to
ask for a motor for a 1973 Chevy Blazer / 350, with a/c. Other
notes say to ask for the "normal" fan motor, not the "premimum" one. It
is said that the shaft on the "premium" motor is too long. I wonder how
you can be confident that you have the right motor if they only list one
(not a "normal" and a "premium" one) ?? Also, I see that Mike Romain
indicates that the "right" motor to ask for is for a 1972 Chevy Blazer
(not a 1973 as indicated on the website article. ). I wonder if anyone
bought a "correct" size motor from NAPA, and could just give me the NAPA
part number ?

Any other comments on making sure I get the right size motor for my 1980
CJ-5 Jeep?


2. Gasket? Will I need to fashion some kind of gasket when the new motor
is put on ? One poster said he had a terrible time getting a new gasket
made. Can I buy a gasket of some sort, or will the old gasket work if
care is taken ?? Any comments?


3. Heater core. I plan to have this job done from the firewall side, and
not take the dash out. Can the heater core be easily removed from the
firewall side ? Will it be obvious to my mechanic if the heater core
needs replacement, or boiling out ? If this is such a hard job, wouldn't
it just be quicker/easier to buy a new heater core ? What is the ballpark
cost of the heater core? Remember, this is a 1980 Jeep, but the core is
not now leaking, but I don't know how good the flow is.


4. On my 1980 CJ-5, would it be easier in the long run to remove the
battery tray ? I have the standard battery and tray.


5. Proper saw for enlarging hole. Which is best, a jigsaw, scroll saw,
or a reciprocal saw with a thin blade ?? I know that a hole-saw will cut
a cleaner, more precise hole, but isn't it true that this can only be done
from the dash side ? (if so, I don't really visualize why???)

-------------------------------------------------

Again, I am not a mechanic, but I work closely with my mechanic and he
doesn't mind if I help him plan, and get the right tools and parts in
advance.

I know this is an old subject, but I really do want to do this upgrade, as I
have always felt that this Jeep was very weak in the heater fan output.
Doubling the output would help a LOT in the dead of winter.

Thanks for helping me on these questions !!!!


--james--

Re: CJ-5 Heater Fan Upgrade Questions
 

I will fill in some...

James wrote:
>
> There were a number of posts and website reviews on upgrading the heater fan
> blower motor for the older vintage cj-5 Jeeps. My Jeep is a 1980 CJ-5.
>
> I have read all the posts that I can find on this, and I would like to
> summarize some questions that still remain for me as I prepare to assist my
> mechanic for getting ready to do this for me.
>
> 1. Motor model. I note that the web article on Off-Road.com says to
> ask for a motor for a 1973 Chevy Blazer / 350, with a/c. Other
> notes say to ask for the "normal" fan motor, not the "premimum" one. It
> is said that the shaft on the "premium" motor is too long. I wonder how
> you can be confident that you have the right motor if they only list one
> (not a "normal" and a "premium" one) ?? Also, I see that Mike Romain
> indicates that the "right" motor to ask for is for a 1972 Chevy Blazer
> (not a 1973 as indicated on the website article. ). I wonder if anyone
> bought a "correct" size motor from NAPA, and could just give me the NAPA
> part number ?

As far as I know the 72 and 73 motors are the same. If in doubt, figure
I made a typo...

The NAPA part number 'might' be 455-1039 or 655-1039, but the person who
posted these never came back to confirm the numbers. I got mine at
Canadian Tire and got the right one first try.

>
> Any other comments on making sure I get the right size motor for my 1980
> CJ-5 Jeep?
>
> 2. Gasket? Will I need to fashion some kind of gasket when the new motor
> is put on ? One poster said he had a terrible time getting a new gasket
> made. Can I buy a gasket of some sort, or will the old gasket work if
> care is taken ?? Any comments?

The gasket is cut out of a chunk of 1/2" or maybe 5/8" foam. I have
been careful on the 3 I have done and managed to reuse the old gaskets
just fine.

>
> 3. Heater core. I plan to have this job done from the firewall side, and
> not take the dash out. Can the heater core be easily removed from the
> firewall side ?

I am not sure this is possible to do with the dash in place, even on the
larger CJ7. Maybe if you take the seats out.....

For 'sure' nothing can be removed from the firewall side except the nuts
holding the heater box in place and the hoses. The one nut dead center
of the valve cover is an SOB!

Will it be obvious to my mechanic if the heater core
> needs replacement, or boiling out ?

Not unless it is totally rotted. The cores aren't visible through the
tubes I don't think.

If this is such a hard job, wouldn't
> it just be quicker/easier to buy a new heater core ? What is the ballpark
> cost of the heater core?

Yup. Costs less than a hundred.

Remember, this is a 1980 Jeep, but the core is
> not now leaking, but I don't know how good the flow is.

I use a garden hose and flush mine. It offers no restriction.

>
> 4. On my 1980 CJ-5, would it be easier in the long run to remove the
> battery tray ? I have the standard battery and tray.

I have done the cutting from the inside so haven't needed to remove the
tray.

>
> 5. Proper saw for enlarging hole. Which is best, a jigsaw, scroll saw,
> or a reciprocal saw with a thin blade ??

Whatever one you can use the best! I have used the first and last.
Although how to get a scroll saw in there?

I have a dremil tool with fiberglass reinforced cutting wheels that work
well on that hole.


I know that a hole-saw will cut
> a cleaner, more precise hole, but isn't it true that this can only be done
> from the dash side ? (if so, I don't really visualize why???)

Unless you have a right angle drill, it won't fit in there.

>
> -------------------------------------------------
>
> Again, I am not a mechanic, but I work closely with my mechanic and he
> doesn't mind if I help him plan, and get the right tools and parts in
> advance.
>
> I know this is an old subject, but I really do want to do this upgrade, as I
> have always felt that this Jeep was very weak in the heater fan output.
> Doubling the output would help a LOT in the dead of winter.
>
> Thanks for helping me on these questions !!!!
>
> --james--

Good Luck.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Re: CJ-5 Heater Fan Upgrade Questions
 

I will fill in some...

James wrote:
>
> There were a number of posts and website reviews on upgrading the heater fan
> blower motor for the older vintage cj-5 Jeeps. My Jeep is a 1980 CJ-5.
>
> I have read all the posts that I can find on this, and I would like to
> summarize some questions that still remain for me as I prepare to assist my
> mechanic for getting ready to do this for me.
>
> 1. Motor model. I note that the web article on Off-Road.com says to
> ask for a motor for a 1973 Chevy Blazer / 350, with a/c. Other
> notes say to ask for the "normal" fan motor, not the "premimum" one. It
> is said that the shaft on the "premium" motor is too long. I wonder how
> you can be confident that you have the right motor if they only list one
> (not a "normal" and a "premium" one) ?? Also, I see that Mike Romain
> indicates that the "right" motor to ask for is for a 1972 Chevy Blazer
> (not a 1973 as indicated on the website article. ). I wonder if anyone
> bought a "correct" size motor from NAPA, and could just give me the NAPA
> part number ?

As far as I know the 72 and 73 motors are the same. If in doubt, figure
I made a typo...

The NAPA part number 'might' be 455-1039 or 655-1039, but the person who
posted these never came back to confirm the numbers. I got mine at
Canadian Tire and got the right one first try.

>
> Any other comments on making sure I get the right size motor for my 1980
> CJ-5 Jeep?
>
> 2. Gasket? Will I need to fashion some kind of gasket when the new motor
> is put on ? One poster said he had a terrible time getting a new gasket
> made. Can I buy a gasket of some sort, or will the old gasket work if
> care is taken ?? Any comments?

The gasket is cut out of a chunk of 1/2" or maybe 5/8" foam. I have
been careful on the 3 I have done and managed to reuse the old gaskets
just fine.

>
> 3. Heater core. I plan to have this job done from the firewall side, and
> not take the dash out. Can the heater core be easily removed from the
> firewall side ?

I am not sure this is possible to do with the dash in place, even on the
larger CJ7. Maybe if you take the seats out.....

For 'sure' nothing can be removed from the firewall side except the nuts
holding the heater box in place and the hoses. The one nut dead center
of the valve cover is an SOB!

Will it be obvious to my mechanic if the heater core
> needs replacement, or boiling out ?

Not unless it is totally rotted. The cores aren't visible through the
tubes I don't think.

If this is such a hard job, wouldn't
> it just be quicker/easier to buy a new heater core ? What is the ballpark
> cost of the heater core?

Yup. Costs less than a hundred.

Remember, this is a 1980 Jeep, but the core is
> not now leaking, but I don't know how good the flow is.

I use a garden hose and flush mine. It offers no restriction.

>
> 4. On my 1980 CJ-5, would it be easier in the long run to remove the
> battery tray ? I have the standard battery and tray.

I have done the cutting from the inside so haven't needed to remove the
tray.

>
> 5. Proper saw for enlarging hole. Which is best, a jigsaw, scroll saw,
> or a reciprocal saw with a thin blade ??

Whatever one you can use the best! I have used the first and last.
Although how to get a scroll saw in there?

I have a dremil tool with fiberglass reinforced cutting wheels that work
well on that hole.


I know that a hole-saw will cut
> a cleaner, more precise hole, but isn't it true that this can only be done
> from the dash side ? (if so, I don't really visualize why???)

Unless you have a right angle drill, it won't fit in there.

>
> -------------------------------------------------
>
> Again, I am not a mechanic, but I work closely with my mechanic and he
> doesn't mind if I help him plan, and get the right tools and parts in
> advance.
>
> I know this is an old subject, but I really do want to do this upgrade, as I
> have always felt that this Jeep was very weak in the heater fan output.
> Doubling the output would help a LOT in the dead of winter.
>
> Thanks for helping me on these questions !!!!
>
> --james--

Good Luck.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Re: CJ-5 Heater Fan Upgrade Questions
 

I will fill in some...

James wrote:
>
> There were a number of posts and website reviews on upgrading the heater fan
> blower motor for the older vintage cj-5 Jeeps. My Jeep is a 1980 CJ-5.
>
> I have read all the posts that I can find on this, and I would like to
> summarize some questions that still remain for me as I prepare to assist my
> mechanic for getting ready to do this for me.
>
> 1. Motor model. I note that the web article on Off-Road.com says to
> ask for a motor for a 1973 Chevy Blazer / 350, with a/c. Other
> notes say to ask for the "normal" fan motor, not the "premimum" one. It
> is said that the shaft on the "premium" motor is too long. I wonder how
> you can be confident that you have the right motor if they only list one
> (not a "normal" and a "premium" one) ?? Also, I see that Mike Romain
> indicates that the "right" motor to ask for is for a 1972 Chevy Blazer
> (not a 1973 as indicated on the website article. ). I wonder if anyone
> bought a "correct" size motor from NAPA, and could just give me the NAPA
> part number ?

As far as I know the 72 and 73 motors are the same. If in doubt, figure
I made a typo...

The NAPA part number 'might' be 455-1039 or 655-1039, but the person who
posted these never came back to confirm the numbers. I got mine at
Canadian Tire and got the right one first try.

>
> Any other comments on making sure I get the right size motor for my 1980
> CJ-5 Jeep?
>
> 2. Gasket? Will I need to fashion some kind of gasket when the new motor
> is put on ? One poster said he had a terrible time getting a new gasket
> made. Can I buy a gasket of some sort, or will the old gasket work if
> care is taken ?? Any comments?

The gasket is cut out of a chunk of 1/2" or maybe 5/8" foam. I have
been careful on the 3 I have done and managed to reuse the old gaskets
just fine.

>
> 3. Heater core. I plan to have this job done from the firewall side, and
> not take the dash out. Can the heater core be easily removed from the
> firewall side ?

I am not sure this is possible to do with the dash in place, even on the
larger CJ7. Maybe if you take the seats out.....

For 'sure' nothing can be removed from the firewall side except the nuts
holding the heater box in place and the hoses. The one nut dead center
of the valve cover is an SOB!

Will it be obvious to my mechanic if the heater core
> needs replacement, or boiling out ?

Not unless it is totally rotted. The cores aren't visible through the
tubes I don't think.

If this is such a hard job, wouldn't
> it just be quicker/easier to buy a new heater core ? What is the ballpark
> cost of the heater core?

Yup. Costs less than a hundred.

Remember, this is a 1980 Jeep, but the core is
> not now leaking, but I don't know how good the flow is.

I use a garden hose and flush mine. It offers no restriction.

>
> 4. On my 1980 CJ-5, would it be easier in the long run to remove the
> battery tray ? I have the standard battery and tray.

I have done the cutting from the inside so haven't needed to remove the
tray.

>
> 5. Proper saw for enlarging hole. Which is best, a jigsaw, scroll saw,
> or a reciprocal saw with a thin blade ??

Whatever one you can use the best! I have used the first and last.
Although how to get a scroll saw in there?

I have a dremil tool with fiberglass reinforced cutting wheels that work
well on that hole.


I know that a hole-saw will cut
> a cleaner, more precise hole, but isn't it true that this can only be done
> from the dash side ? (if so, I don't really visualize why???)

Unless you have a right angle drill, it won't fit in there.

>
> -------------------------------------------------
>
> Again, I am not a mechanic, but I work closely with my mechanic and he
> doesn't mind if I help him plan, and get the right tools and parts in
> advance.
>
> I know this is an old subject, but I really do want to do this upgrade, as I
> have always felt that this Jeep was very weak in the heater fan output.
> Doubling the output would help a LOT in the dead of winter.
>
> Thanks for helping me on these questions !!!!
>
> --james--

Good Luck.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Re: CJ-5 Heater Fan Upgrade Questions
 

Thank you very much Mike !!

I will look for any other comments.


--james--

Re: CJ-5 Heater Fan Upgrade Questions
 

Thank you very much Mike !!

I will look for any other comments.


--james--

Re: CJ-5 Heater Fan Upgrade Questions
 

Thank you very much Mike !!

I will look for any other comments.


--james--

Re: CJ-5 Heater Fan Upgrade Questions
 

On Sat, 28 Oct 2006, James wrote:

> There were a number of posts and website reviews on upgrading the heater fan
> blower motor for the older vintage cj-5 Jeeps. My Jeep is a 1980 CJ-5.
[snip]

> 1. Motor model. I note that the web article on Off-Road.com says to
> ask for a motor for a 1973 Chevy Blazer / 350, with a/c. Other
> notes say to ask for the "normal" fan motor, not the "premimum" one. It
> is said that the shaft on the "premium" motor is too long. I wonder how
> you can be confident that you have the right motor if they only list one
[snip]

Take your old motor with you. The critical match is the shaft length, and
the differnce will be obvious. The problem seems to be that someplace
along the line -- probably from GM itself -- there was confusion about
which motor was associated with which part number. Some suppliers will
pull up the right part, some the other one (AutoZone, for one, will pull
the wrong one using the web site's info). Considering the millions of
parts available, one screwup isn't so bad.


> Any other comments on making sure I get the right size motor for my 1980
> CJ-5 Jeep?

Take your old one with you.


> 2. Gasket? Will I need to fashion some kind of gasket when the new motor
> is put on ? One poster said he had a terrible time getting a new gasket
> made. Can I buy a gasket of some sort, or will the old gasket work if
> care is taken ?? Any comments?

I managed to stretch my old gasket to fit, but it was tight. Go slowly,
carefully.


> 3. Heater core. I plan to have this job done from the firewall side, and
> not take the dash out. Can the heater core be easily removed from the
> firewall side ? Will it be obvious to my mechanic if the heater core
> needs replacement, or boiling out ? If this is such a hard job, wouldn't
> it just be quicker/easier to buy a new heater core ? What is the ballpark
> cost of the heater core? Remember, this is a 1980 Jeep, but the core is
> not now leaking, but I don't know how good the flow is.

You can't get the blower motor out with the heater box in place. You
can't get the heater box out with the dash in place, but you don't have to
pull the dash all the way off, either.

The heater core is kept in place by a metal panel held down by about a
dozen coarse-thread screws on the forward face of the heater box. There
is no way to remove it through the firewall.

Removing/replacing the heater box is such a pain in the arse. I recommend
simply replacing the core now, while you have the damned thing apart
rather than waiting until it leaks -- and it will.

Quadratec retails a new core for about 50 bucks.

Salvage your control cables, if you can. The replacement ones look better
made than they are. I've broken two in as many years. Beware that the
short cable that links (I think) the vent door with the cowl door is not
in production.


> 4. On my 1980 CJ-5, would it be easier in the long run to remove the
> battery tray ? I have the standard battery and tray.

You'll probably be happiest if you pull the tray and the right fender, but
that's just me. Be aware that bolts will break when you try to get them
off.


> 5. Proper saw for enlarging hole. Which is best, a jigsaw, scroll saw,
> or a reciprocal saw with a thin blade ?? I know that a hole-saw will cut
> a cleaner, more precise hole, but isn't it true that this can only be done
> from the dash side ? (if so, I don't really visualize why???)

I don't see why the hole saw would only work from the dash side, but it
does require building a jig. I did mine the hard way: Scribed a circle
and used a die grinder for the rough and a file for the fine. Be
prepared for a lot of trial fitting and revision. When you do the trial
fit, leave out the heater core to reduce danage to the pipes.



> I know this is an old subject, but I really do want to do this upgrade, as I
> have always felt that this Jeep was very weak in the heater fan output.
> Doubling the output would help a LOT in the dead of winter.

It is well worth the effort.




--
"I defer to your plainly more vivid memories of topless women with
whips....r"
R. H. Draney recalls AFU in the Good Old Days.

Re: CJ-5 Heater Fan Upgrade Questions
 

On Sat, 28 Oct 2006, James wrote:

> There were a number of posts and website reviews on upgrading the heater fan
> blower motor for the older vintage cj-5 Jeeps. My Jeep is a 1980 CJ-5.
[snip]

> 1. Motor model. I note that the web article on Off-Road.com says to
> ask for a motor for a 1973 Chevy Blazer / 350, with a/c. Other
> notes say to ask for the "normal" fan motor, not the "premimum" one. It
> is said that the shaft on the "premium" motor is too long. I wonder how
> you can be confident that you have the right motor if they only list one
[snip]

Take your old motor with you. The critical match is the shaft length, and
the differnce will be obvious. The problem seems to be that someplace
along the line -- probably from GM itself -- there was confusion about
which motor was associated with which part number. Some suppliers will
pull up the right part, some the other one (AutoZone, for one, will pull
the wrong one using the web site's info). Considering the millions of
parts available, one screwup isn't so bad.


> Any other comments on making sure I get the right size motor for my 1980
> CJ-5 Jeep?

Take your old one with you.


> 2. Gasket? Will I need to fashion some kind of gasket when the new motor
> is put on ? One poster said he had a terrible time getting a new gasket
> made. Can I buy a gasket of some sort, or will the old gasket work if
> care is taken ?? Any comments?

I managed to stretch my old gasket to fit, but it was tight. Go slowly,
carefully.


> 3. Heater core. I plan to have this job done from the firewall side, and
> not take the dash out. Can the heater core be easily removed from the
> firewall side ? Will it be obvious to my mechanic if the heater core
> needs replacement, or boiling out ? If this is such a hard job, wouldn't
> it just be quicker/easier to buy a new heater core ? What is the ballpark
> cost of the heater core? Remember, this is a 1980 Jeep, but the core is
> not now leaking, but I don't know how good the flow is.

You can't get the blower motor out with the heater box in place. You
can't get the heater box out with the dash in place, but you don't have to
pull the dash all the way off, either.

The heater core is kept in place by a metal panel held down by about a
dozen coarse-thread screws on the forward face of the heater box. There
is no way to remove it through the firewall.

Removing/replacing the heater box is such a pain in the arse. I recommend
simply replacing the core now, while you have the damned thing apart
rather than waiting until it leaks -- and it will.

Quadratec retails a new core for about 50 bucks.

Salvage your control cables, if you can. The replacement ones look better
made than they are. I've broken two in as many years. Beware that the
short cable that links (I think) the vent door with the cowl door is not
in production.


> 4. On my 1980 CJ-5, would it be easier in the long run to remove the
> battery tray ? I have the standard battery and tray.

You'll probably be happiest if you pull the tray and the right fender, but
that's just me. Be aware that bolts will break when you try to get them
off.


> 5. Proper saw for enlarging hole. Which is best, a jigsaw, scroll saw,
> or a reciprocal saw with a thin blade ?? I know that a hole-saw will cut
> a cleaner, more precise hole, but isn't it true that this can only be done
> from the dash side ? (if so, I don't really visualize why???)

I don't see why the hole saw would only work from the dash side, but it
does require building a jig. I did mine the hard way: Scribed a circle
and used a die grinder for the rough and a file for the fine. Be
prepared for a lot of trial fitting and revision. When you do the trial
fit, leave out the heater core to reduce danage to the pipes.



> I know this is an old subject, but I really do want to do this upgrade, as I
> have always felt that this Jeep was very weak in the heater fan output.
> Doubling the output would help a LOT in the dead of winter.

It is well worth the effort.




--
"I defer to your plainly more vivid memories of topless women with
whips....r"
R. H. Draney recalls AFU in the Good Old Days.

Re: CJ-5 Heater Fan Upgrade Questions
 

On Sat, 28 Oct 2006, James wrote:

> There were a number of posts and website reviews on upgrading the heater fan
> blower motor for the older vintage cj-5 Jeeps. My Jeep is a 1980 CJ-5.
[snip]

> 1. Motor model. I note that the web article on Off-Road.com says to
> ask for a motor for a 1973 Chevy Blazer / 350, with a/c. Other
> notes say to ask for the "normal" fan motor, not the "premimum" one. It
> is said that the shaft on the "premium" motor is too long. I wonder how
> you can be confident that you have the right motor if they only list one
[snip]

Take your old motor with you. The critical match is the shaft length, and
the differnce will be obvious. The problem seems to be that someplace
along the line -- probably from GM itself -- there was confusion about
which motor was associated with which part number. Some suppliers will
pull up the right part, some the other one (AutoZone, for one, will pull
the wrong one using the web site's info). Considering the millions of
parts available, one screwup isn't so bad.


> Any other comments on making sure I get the right size motor for my 1980
> CJ-5 Jeep?

Take your old one with you.


> 2. Gasket? Will I need to fashion some kind of gasket when the new motor
> is put on ? One poster said he had a terrible time getting a new gasket
> made. Can I buy a gasket of some sort, or will the old gasket work if
> care is taken ?? Any comments?

I managed to stretch my old gasket to fit, but it was tight. Go slowly,
carefully.


> 3. Heater core. I plan to have this job done from the firewall side, and
> not take the dash out. Can the heater core be easily removed from the
> firewall side ? Will it be obvious to my mechanic if the heater core
> needs replacement, or boiling out ? If this is such a hard job, wouldn't
> it just be quicker/easier to buy a new heater core ? What is the ballpark
> cost of the heater core? Remember, this is a 1980 Jeep, but the core is
> not now leaking, but I don't know how good the flow is.

You can't get the blower motor out with the heater box in place. You
can't get the heater box out with the dash in place, but you don't have to
pull the dash all the way off, either.

The heater core is kept in place by a metal panel held down by about a
dozen coarse-thread screws on the forward face of the heater box. There
is no way to remove it through the firewall.

Removing/replacing the heater box is such a pain in the arse. I recommend
simply replacing the core now, while you have the damned thing apart
rather than waiting until it leaks -- and it will.

Quadratec retails a new core for about 50 bucks.

Salvage your control cables, if you can. The replacement ones look better
made than they are. I've broken two in as many years. Beware that the
short cable that links (I think) the vent door with the cowl door is not
in production.


> 4. On my 1980 CJ-5, would it be easier in the long run to remove the
> battery tray ? I have the standard battery and tray.

You'll probably be happiest if you pull the tray and the right fender, but
that's just me. Be aware that bolts will break when you try to get them
off.


> 5. Proper saw for enlarging hole. Which is best, a jigsaw, scroll saw,
> or a reciprocal saw with a thin blade ?? I know that a hole-saw will cut
> a cleaner, more precise hole, but isn't it true that this can only be done
> from the dash side ? (if so, I don't really visualize why???)

I don't see why the hole saw would only work from the dash side, but it
does require building a jig. I did mine the hard way: Scribed a circle
and used a die grinder for the rough and a file for the fine. Be
prepared for a lot of trial fitting and revision. When you do the trial
fit, leave out the heater core to reduce danage to the pipes.



> I know this is an old subject, but I really do want to do this upgrade, as I
> have always felt that this Jeep was very weak in the heater fan output.
> Doubling the output would help a LOT in the dead of winter.

It is well worth the effort.




--
"I defer to your plainly more vivid memories of topless women with
whips....r"
R. H. Draney recalls AFU in the Good Old Days.