What a PITA this was. We'll it's done, doesn't leak, and all parts involved look new again. Now I plan to install an aftermarket AC and want to know if I need to remove my stock evaporator core or if I can just leave it there and it won't be in the way to install an aftemarket setup. If I can leave it I'll just snip off the tubes inside the fender where they won't be seen and call it a day. Much easier than pulling the fender. Let me know folks!:)

Is there room to mount an aftermarket system without removing the old one? Possibly an underdash type?
The aftermarket systems I'm familiar with require removing much of the old system. What system do you have in mind?.

Just a thought; Why not repair the old system or build a new system around the existing parts? If you have a good evaporator and the air distribution system works (or is repairable), the battle is half won from the start. The cost is about the same and sometimes less. (It's strictly my opinion that the original system works much better than any aftermarket system.)

Either way you proceed, you should bite the bullet and remove the evaporator to at least clean it and the box. Years of dirt and debris block airflow and can cause some nasty smells.

My opinion is that if you don't mind "the box" hanging off your firewall you'll be happier with factory air. I've added air to my '55 and to the '69 and the heat & air is either on or off. Factory allows blending outside air and that's not an option with add-on. The '69 wasn't an a/c car, but I installed a/c dash so I wouldn't have anything hanging under the dash. I've added pics to my signature showing a/c lines routed down and behind wheel well so nothing shows on firewall and I've finally got Derale fans done.