congrats on the new car Adrian! give it the loves it deserves and it will give lots of smiles in return!
check out this thread on the foam coming out of the vents:
http://986forum.com/forums/general-discussions/60055-heater-not-crispy-enough.html
sounds like another winter project for you as it's time consuming more than anything.
good luck and keep us posted! always nice to see someone working on and enjoying their boxster.