2000 Carrera 2 - Doors of the air housing assembly

[Philip54]

The foam covering the doors/flaps of the air housing assembly (where the A/C evaporator is) is failing and pieces of foam are coming out of the A/C vents.   I intend to have the doors replaced.  I have spare door frames (uncovered) and I would like to cover them with suitable material in preparation for the replacement (Porsche does not sell the doors separately from the air housing assembly).  Could somebody make a recommendation on the material to use?  I am concerned about both durability and the ability of the doors to seal properly when closed. 

 

Thanks in advance

[rb101]

I had some thin foam (forgot where it came from) and I just used some 3m spray adhesive to apply it to both sides of the door.  Worked fine, no issues after 6 months.  

[RRocket]

I'm having this EXACT same problem.

 

Where do I find the doors/assembly??

[Ahsai]

Post #1 here talks about the foam VW use with p/n. Looks promising. http://forums.thecarlounge.com/showthread.php?3563354-Foam-Replacement-Kit-for-Heater-Box-Flaps

[Philip54]

I'm having this EXACT same problem.

 

Where do I find the doors/assembly??

Try a used parts shop

[Philip54]

Post #1 here talks about the foam VW use with p/n. Looks promising. http://forums.thecarlounge.com/showthread.php?3563354-Foam-Replacement-Kit-for-Heater-Box-Flaps

Many thanks, Ahsai!

[Porsche Pilot]

I just did this a few weeks ago. I used the widest window weatherstripping I could find at Lowes. It's a one side adhesive foam. I wrapped it all around the the door, wrapping around the edges. I then covered the whole thing in duct tape. Kind of a redneck fix but it works great. I had zero foam left on the door/flap. A/C is nice and cold now.

Here is the DIY link: http://www.renntech.org/forums/tutorials/article/121-fixed-my-lack-of-heat-problem-here-is-the-procedure/

Edited June 19, 2014 by Porsche Pilot

[Porsche Pilot]

This is how the door looked when I took it out.

[Ahsai]

Post #1 here talks about the foam VW use with p/n. Looks promising. http://forums.thecarlounge.com/showthread.php?3563354-Foam-Replacement-Kit-for-Heater-Box-Flaps

Many thanks, Ahsai!

Btw, that part seems to be only available here http://www.busdepot.com/155298121

[RRocket]

 

I'm having this EXACT same problem.

 

Where do I find the doors/assembly??

Try a used parts shop

 

 

 

LOL...No, no..LOL.......I mean where in the car is the door/assembly located!  :)

[Porsche Pilot]

It is inside the heater core which is accessed under the cowl.

[Philip54]

 

 

Post #1 here talks about the foam VW use with p/n. Looks promising. http://forums.thecarlounge.com/showthread.php?3563354-Foam-Replacement-Kit-for-Heater-Box-Flaps

Thanks, Ahsai

Btw, that part seems to be only available here http://www.busdepot.com/155298121

 

 

 

Thanks, Ahsai

[Philip54]

I just did this a few weeks ago. I used the widest window weatherstripping I could find at Lowes. It's a one side adhesive foam. I wrapped it all around the the door, wrapping around the edges. I then covered the whole thing in duct tape. Kind of a redneck fix but it works great. I had zero foam left on the door/flap. A/C is nice and cold now.

Here is the DIY link: http://www.renntech.org/forums/tutorials/article/121-fixed-my-lack-of-heat-problem-here-is-the-procedure/

 

Thanks for the link and the suggestions.

[Porsche Pilot]

It's not an overly complicated procedure, just a bit fiddly. If you decide to perform the DIY I can talk you through any issues. The whole thing took me about 5 hours with a few beer breaks in between. The hardest part was getting under the dash as I had to contort myself in ways only a skilled Russian gymnast can.

[RRocket]

So if you end up making the door/flap essentially "solid" with duct tape...why wasn't the door solid from the factory?  What's the point of the round cut-outs?

[Porsche Pilot]

Weight savings are my guess.

[onempty]

I am working on a 1999 911 and I am trying to get to the metal air flap under the cowl. I have it all apart but I wanted to know if there is a special way to remove the heater (Part with the coolant lines) out of the way. I took the two bolts out and it moves but not enough to get out.