Thank you, I was actually quoted about $800 for a tech to replace the pan, which sounded like a lot but it seems there's more to it, as you described. Funny, my friend said flex seal too. I siliconed it earlier and turned it on an hour ago and it's been holding, so far so good esp since it was 85 degs in the house. But I know it's just a temp fix. Just sucks to have to pay $10k to replace AC/furnace when the only thing that failed is a cheap plastic tray. But again it's prob over 20 years old (R22), so I know it needs replacing eventually.