I posted earlier today about a wet passenger floor from what appeared to be a clogged A/C condensate drain. After standing on my head most of the afternoon trying to open a clogged drain, I was able to get a little bit of an eyeball on the drain opening which does not seem to be clogged.

What I did find was a very small chuck of plastic stuck to the butyl tape/putty which I had removed from around the lower A/C line entering the evaporator. This piqued my curiosity and provoked a hairy eyeball examination of the area of the evaporator around the A/C line penetration. It seems the son-of-a-bitch who R&R'ed the evaporator also cracked the evaporator cover in the worst place possible - at the bottom!

I guess the next step is to see if it looks like I can remove the evaporator cover without pulling the evaporator, then find out if the cover is even available.

Barring that possibility, I'll have to go to town with some butyl dum-dum. The problem with the butyl route is that there is now water trapped in the various nooks and crannies which have to be sealed from the outside, especially the crack in the cover and although butyl tape is a gift from the gods, about the only thing it won't stick to is a wet surface.

As always, any reasoned input will be appreciated.

Rich