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The best advice I can give you is to buy a kit to fit your rig and follow the directions, you can always ask on here for more details, but for now you are asking somebody to write you a book.
Mike 04 GT, I bought a truck w/ the aftermarket a/c system that fit behind the glove box and only had to drill 3 small holes in the firewall for the drain and 2 hoses and I installed factory brackets on engine. Been using it for years w/ no problem. Forgot to mention, that I took factory a/c dash and used it in truck so it looks stock w/ exception of 2 ***** next to center vent. Some guys say that you can take firewall from donor truck as template and cut to fit and adapt factory system, me, I have not yet mastered that ability....but I am getting close as the years catch up to me! They also sell the under dash units, never had one so I don't know how they look or work, sorry. The system I set up was easy to install. I may be parting out the s/c that it is in soon, pm me if you are interested, as a later option.
I have a couple pictures in my gallery of my 79 no AC cab and what the AC cab firewall looks like.
Do you have any junk yards you can check in?
When I bought my parts it was 10 years ago, however there are two yards in my area that have a few of these AC trucks. I more than likely would be able to pick up what I need now for around 175.00, might be less.
These 2 yards are more focused on steel prices now more than selling parts, and the 175.00 I would pay is worth far more than what scrap prices would bring for the weight of the items, however I would have to spend a little time there removing these parts myself since they would not want to waste thier own time with it.
I do however visit these yards enough to have established a decent working relationship with the owners.
I remember spending approx 4 "SCORCHING" hours in the junk yard that July day tagging and removing all the parts I needed and cutting the firewall section.
I try to avoid the more well known junk yards and search out the smaller ones with less overhead. They are still out there.
What is really sad is that when I cut the cab in the photo it was summer 1993, the truck sat in pieces for 13 years before I started working on it again and by then my focus changed after I put in the fatman IFS and the Lincoln 4.6 engine in it.
Believe it or not I welded in a solid piece of steel over the existing firewall to accomodate the 93 Lincoln Mark 8 AC plenum that is bolted to the firewall now along with the dash.
All the parts I had in boxes for the AC and the template I cut from the donor firewall I sold on ebay last fall.
When I cut the firewall section from the donor I used a small pair of metal snips that are made by Jilson co. inc. They will get in some really tight areas and I also had 2 replacement blades available when I cut it out but only needed one(yes the blades will break if they are in a bind) There web site is listed below.
A good battery powered sawzall would work well too.