Alright, i finally got the foam that i ordered.
The right stuff is minicel. I ordered it from
www.foambymail.com because they have fairly decent prices.. however it took almost two weeks to get the foam.
Here is a direct link to the foam:
http://www.foambymail.com/MC2-/minicel-foam-2lb.html
Its the 2lb minicel. You will want to order in 1".
When i ordered, i actually bought 3/4". This was perfect for the fresh air intake foam seal, but not for the firewall seal around where the Blower motor goes. I ended up having to carefully attach another peice of foam to the seal i cut originally. This worked great for me, but if i would do it again i would use the proper size to make the seal for this area. I just traced the old seal on the new foam and then cut. An electric carving knife is your friend here.. you wont want to try and use scissors.
I also ordered some 1/8" foam from the following link:
http://www.foambymail.com/NE/neoprene-foam-sheets.html
Its neoprene.. the regular density is what i ordered. I used this for the blend doors, and i also could have used this for the upper section of the heater box.. but the current foam in there was just fine so i left it alone.
Dap Contact cement was purchased to attach the foam to the blend doors and plastic. I bought both the gel kind, and the regular kind. I found the Gel to be much easier to use and work with a small paint brush. I didnt seem to make as much of a mess with it either.
I also purchased some 1/8" sticky back foam from Ace Hardware that i used in all the seam areas.. this was much easier than trying to attach with the contact cement in the smaller areas.
Finally, i purchased one of those foam pipe insulation things and cut just a really small peice for the evaporator core drain. You can get these things cheap just about anywhere. I didnt buy the harder foam kind (probably polystyrene) but the rubbery kind (like neoprene).
I have a quick question...
The original blend door foam had a "wedge" piece on it. Thats the best i can describe it. Anyway, i thought about attempting to replicate this wedge, but im wondering if i even need to. Im not sure of its actual purpose... the only thing i can think of is some additional weight on one side of the door but i dont really know. Thoughts on this?
Thanks!
