rust holes and leaves in heater plenum?

[wishihadars1800]

hey i recently took the rubber cover of my heater plenum not sure if its called that and found two rust holes not massive but enough to stick my two fingers in and its chock a block full of leaves and since its a heater plenum? if it gets hot would it start a fire? but anyways i wanna get all the leaves out but im finding it hard because im not sure how or if you can get it off or a way to get to the leaves out.

[Paul Dunstan]

I'm affraid this is a common fault with the Escort and 90% of them rust there for that very reason. The rust is generally worse than first appears once the area is accessible

The only way to do it properly is to remove the cover and remove the debris, then repair the area. Once done you need to re-install the cover.

The only other way to clear it out is to remove the heater and fan assy from under the dash and get in from there in an attempt to shift the rubbish. Not an especially pleasant or difficult job but it might enable you to see the extent of the rust more accurately from underneath.

Good luck.

[jpayne]

wish!

to clear the majority of rubbish I found a high preassure air hose worked well, plenty of water and a tad bit of good luck. As paul says this is a common problem and you will soon discover the extent of the rust as too how much water makes it inside. Not many of us are lucky in this instance and rust repair is usually a common route taken here. Remove the heater bowl with the tried and tested spot weld removing drill bit, cheap and easy. Once removed the assesment of the area can be properly undertaken, some may be just small holes others may be tin worm everywhere, some may be a combination with dodgy previous repairs, read filler, fibreglass, coke cans or old loaves of bread???
repair always requires some form of fabrication as the panels are complex shapes and need to fit the heater box below.
I wouldnt worry about fire as the heater core does not get hot enough, shouldnt be touching leaves or debris and more than likely the debris is wet and muddy anyway.

Good luck

[Rod Jacome]

Have a look at Rod Jacome's restoration in the members projects and you will see how far the rust can take you.