HVAC box foam madness

[Jess]

So I have some time and I decided to pull my dash and HVAC box to fix my water leaks which I originally thought was coming from the fresh air intake but it appears now it's all the blower motor seal/foam. When I pulled the dash I discovered all kinds of exposed wires, dirty grounds, smashed/pancaked heater tubes and all sorts of nonsense so I'm making it a general clean up. It was also an excuse to put as much Dynamat (well, a knock off) on the firewall as I could.

 

Anyway, now that I'm sitting here with this nonsense, I'm kind of regretting it...

 

I didn't find it all that complicated to take apart. It was pretty straightforward, the issue is just the foam is all rotting and in horrible condition. The only part's I can find are these but they're listed as 97+ and I have an 89. They look right but even if I got those and they worked all the blend door and interior foam is trashed.

 

In another post I found that someone used this product for the blower/fresh air seals and this for the blend doors. Mine is in good enough shape that I could probably use it as a template so right now I'm leaning towards that being my best option but I'm curious if anyone has any magical suggestions (besides set it on fire). There's way more foam in the box than I thought there was.

 

I'm going to replace my heater core/evap/blower while I'm at it but that's pretty much killing my budget atm lol.

[Akula69]

When I rebuilt mine I went to hobby lobby and used a foam sheet that had adhesive backing on it. It's similar to this but better quality:

 

http://www.walmart.com/ip/28600364?wmlspartner=wlpa&adid=22222222227019075960&wl0=&wl1=g&wl2=c&wl3=40944797072&wl4=&wl5=pla&wl6=78886470752&veh=sem

 

the 6mm thickness works well with all the moving parts, and it is also mold-proof as a bonus.

I re-used my blower motor-to-firewall seal and the heater core/Evap core seals as I could not find them in this area, but Amazon has a product which I have seen used for those two:

 

http://www.amazon.com/Fastcap-Kaizen-Foam-57mm-Black/dp/B007J2JJYK/ref=sr_1_1?s=arts-crafts&ie=UTF8&qid=1455023742&sr=1-1&keywords=kaizen+foam

 

See what you think. The project is much easier then most folks believe.