Custom built Heater & AC housing

[Mutt's37Buick]

Has anyone ever custom built a Heater & AC housing for under the dash?
I have a complete evaporator & heater unit from a '95 Roadmaster, but it is too large to fit under in my '37 Roadmaster dash. Thought I may be able to fab a smaller housing that can be used with the heater core, evaporator and blower. Fewer controls, but custom made to fit under my dash.
1) Has anyone done this, and how did it turn out?
2) What material would you recommend for the housing?
Pictures would be great.
Thanks
Mutt

 

[Yodaforce]

I have always just used a universal unit minus compressor and condenser.

I personally have never known anyone to fabricate the housing unit, but just the duct work or splitter adapted to the main housing from a donor.

http://www.nostalgicairparts.com/air-conditioning/ud-100-under-dash-air-only-evaporator-unit-85.php

 

[Mutt's37Buick]

Thanks for your help
Mutt

 

[Bamamav]

Why not just build a box out of aluminum or sheetmetal? You could make it the size you needed. Just have to have room for the air to flow through the cores to the vents.

 

[Mutt's37Buick]

Alum might be ok. Plastic or fiberglass may be better option since there will be condensation. The evaporator core I have is 10.5" tall x 9" wide x 2.88 thick. The heater core is 8.38 x 6.06 x 1.25 thick. A rectangular duct can be up to 13" wide and still slide up behing the dash.
Thanks
Mutt