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Ended up going with "holesaw method" (not to be confused with "chainsaw method"!). See link for writeup:
http://forums.turbobricks.com/archive/index.php/t-57613.html
Worked very well. Didn't have to dremel out anything, particularly inside of blower housing to get motor out. This is why the loss of air pressure, I would suspect, with "chainsaw method".
Only had to remove left cover, and was glad to save some of the pain. It was fairly difficult to get all of the clips off. Also, quite difficult to "pop" the cover out of the upper duct housing. I did not remove the dash, and kept all ductwork in place. As pointed out in the article above, however, it was able to slide out after the tacky weatherstripping connecting the duct to the blower cover was freed up.
Feel very good about the end result, and the only negative is a 1-1/2 inch hole on the left side that was sealed up with duct tape. learned a lot about the insides of the inside over the weekend.
Total work time probably about 7 hours. Would have been a bit longer if I didn't take occasional breaks to mentally regroup. Oh, and neighbors house caught on fire, so called 911 and got a bit distracted with that! (no one hurt .. fluke electrical issues in 1929 house).
iveand
91 240 wagon 155K 5 speed
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