I'll see what I can do about the drain plug. It seems to be working though, it drips a ton after a long drive in the florida heat with the ac on.
Were the drain holes a recall item or do all cars have them?
They were a service bulletin item. If you're sure the noise only happens with the A/C on, I'm not sure how they could be the culprit - if there's water in there, it'll be in there all the time. But it's probably still a good idea to have them done anyway as you really don't want to deal with replacing the blower motor controller/resistors if they get wet.