After fighting leaks for a while I decided to pull the cowling off the AC and check seals etc. The workings look really rough, lots of rust and bubbling, so I guess it's time for a new AC. I have the tech guys and muscle available, and hope to get the new unit for under 400 bucks, no heat strip. I'll take plenty of pix and let everyone know what I run into for the archives.

Holler if you need a hand.

Thanks Ug, I got the unit apart today and discovered a clitch in installation. This isn't the original so I can't blame Barth. On the front of the underside of the Mach unit there are two little plastic tabs, one on each side. The right one was properly aligned but the left one was stuck between the roof and the flange and caused the aluminum to curl and the seal to not seat properly. This probably didn't have any effect for many years, but it has recently, so because somebody way back when didn't pay attention, I have to put in a new ceiling. If this was a stick and staple POS it wouldn't have lasted this long and no one would have known, but if you're working on a Barth it might be a good idea to do it right. I'll put a new seal on it and re-install the old unit for now, just because it's so simple that if I have to replace it in a few months it's no biggy.