Split the evaporator box apart & can't get it back toget

[general bacardi]

My A/C system had a leak, and in an effort to diagnose it, I took off the lower half of the plastic box that covers the evaporator and expansion valve. (Turns out the evap and valve were fine, so this was all for nothing.)

The damn thing will not go back together; I've tried for hours on end. I can get two of the 3 screw holes in the front to line up, but none of the rear ones. I can get it so the surfaces on the left side (behind the console) line up and seal, but not the right side (the side that connects to the housing around the blower motor) It won't line up, and half of the air goes out the gap instead of thru the vents.

Any tricks to getting this thing back together????

[Legacy777]

Check to make sure you are putting it together correctly. Also check that the evaporator is sitting properly in the styrofoam.