01-12-2022, 04:07 PM
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#1
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Registered User
Join Date: Jun 2006
Location: Indianapolis, IN
Posts: 29
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DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents)
I was reading VW forums and noticed that the Golf/Jetta/Beetle/Passat have the same HVAC blend door foam issues that Porsches do. Some users have started using plastic plugs to block the holes in the blend doors. The size and number of those plugs looked very similar to the Porsche blend doors, so I ordered as set…and they fit!
I put together a quick video fo the installation process. Hopefully someone else finds this useful/helpful.
Porsche 911 Boxster Blend Door Repair Plugs (fix foam coming out of vents)
Video: https://youtu.be/ZiFFllCzlxc
DSP Blend Door Plugs
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01-14-2022, 12:45 PM
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#2
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Registered User
Join Date: Jan 2014
Location: New Jersey
Posts: 1,631
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Quote:
Originally Posted by Carlton Bale
I was reading VW forums and noticed that the Golf/Jetta/Beetle/Passat have the same HVAC blend door foam issues that Porsches do. Some users have started using plastic plugs to block the holes in the blend doors. The size and number of those plugs looked very similar to the Porsche blend doors, so I ordered as set…and they fit!
I put together a quick video fo the installation process. Hopefully someone else finds this useful/helpful.
Porsche 911 Boxster Blend Door Repair Plugs (fix foam coming out of vents)
Video: https://youtu.be/ZiFFllCzlxc
DSP Blend Door Plugs
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Cool! If I ever need to open mine up again I'll do it!
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Current: 2022 718 Cayman GT4, PDK bone stock (the dark side).
Former: 2003 S, 3.6 LN Nickies, ARP rod bolts, under-drive pulley, Fabspeed sport headers, Softronic tune, 987 airbox 987 motor mount, Function-First Sport motor mount insert, Ben's short shifter, Nine8Six projector headlights & center caps, ROW M030, stainless flexible brake lines, B-K rollbar extension & fire extinguisher mount, hardtop
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01-17-2022, 06:38 AM
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#3
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Registered User
Join Date: Apr 2014
Location: Alabama
Posts: 122
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Those little plugs look like the way to go, well worth the cost. I've done that repair using fiberglass three times. The plugs would eliminate the mess and the curing time of fiberglass, saving about three hours on the whole project.
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01-17-2022, 08:38 PM
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#4
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Registered User
Join Date: Sep 2008
Location: Florida
Posts: 2,497
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Great video, thanks for posting!
I feel so old school for using duct tape...Luckily, we don't get too cold here in NW Florida.
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01-18-2022, 03:34 AM
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#5
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Motorist & Coffee Drinker
Join Date: Jul 2014
Location: Oklahoma
Posts: 3,772
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Quote:
Originally Posted by dghii
... I feel so old school for using duct tape. ...
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It is an HVAC *duct*, so ...correct use of the tape.
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I am not an attorney, mechanic, or member of the clergy. Following any advice given in my posts is done at your own peril.
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01-18-2022, 03:59 PM
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#6
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Registered User
Join Date: Jun 2006
Location: Indianapolis, IN
Posts: 29
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I think the high-temp duct tape will work just as well as the plugs.
I didn’t know about the fiberglass repair option. That does sound labor intensive, especially for someone like me who is terrible at fiberglass work.
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01-19-2022, 11:03 AM
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#7
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Registered User
Join Date: Jan 2014
Location: New Jersey
Posts: 1,631
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Quote:
Originally Posted by Carlton Bale
I think the high-temp duct tape will work just as well as the plugs.
I didn’t know about the fiberglass repair option. That does sound labor intensive, especially for someone like me who is terrible at fiberglass work.
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I'm with you on that! It was hard enough getting the strips of aluminum tape in place, I couldn't imagine laying glass tape and brushing resin onto the bled doors using the shortcut method and not making a mess all over, and having the resin run down and possibly harden in places that would jam the doors. My hat's off to someone who can do that!
__________________
Current: 2022 718 Cayman GT4, PDK bone stock (the dark side).
Former: 2003 S, 3.6 LN Nickies, ARP rod bolts, under-drive pulley, Fabspeed sport headers, Softronic tune, 987 airbox 987 motor mount, Function-First Sport motor mount insert, Ben's short shifter, Nine8Six projector headlights & center caps, ROW M030, stainless flexible brake lines, B-K rollbar extension & fire extinguisher mount, hardtop
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01-30-2022, 08:01 AM
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#8
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Registered User
Join Date: Feb 2006
Location: Virginia
Posts: 1,712
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Thank you for posting this information. I ordered my plugs and will install them before spring. I'm planning to use clear RTV sealant for a neater appearance. (I know it is unlikely that anyone else will ever see it.)
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2000 Arctic Silver/Black, Hard Top, On Board Computer
PNP Rear Speakers, HAES 6-Channel Amp, Avic Z140BH,
Painted Bumperettes, 2004 (OEM) Top, Homelink integrated in dash with Targa switch, 997 Shifter, Carrera Gauge Cluster with silver gauge faces, heated 997 adaptive sports seats, Litronics, silver console
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02-06-2022, 04:29 PM
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#9
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Registered User
Join Date: Oct 2020
Location: KY
Posts: 1,216
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Great video, thanks for posting!
I have a stupid question - why are there holes in these panels to start with?
Sent from my SM-G970U1 using Tapatalk
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2000 Box Base, Renegade Stage 1 performance mods complete, more to come
When the owners manual says that the laws of physics can't be broken by this car, I took it as a challenge...
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02-07-2022, 03:23 AM
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#10
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Registered User
Join Date: Jun 2006
Location: Indianapolis, IN
Posts: 29
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Quote:
Originally Posted by ike84
Great video, thanks for posting!
I have a stupid question - why are there holes in these panels to start with?
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It's not a stupid question – that blend door is definitely a stupid design! My guess is that it was a cost reduction. The end result is about 1/3 less material.
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02-08-2022, 05:17 PM
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#11
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Registered User
Join Date: Sep 2008
Location: Florida
Posts: 2,497
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Quote:
Originally Posted by Carlton Bale
It's not a stupid question – that blend door is definitely a stupid design! My guess is that it was a cost reduction. The end result is about 1/3 less material.
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It isless mate rial but I'd bet there's another 'engineering' reason as you wouldn't cut different shape holes just to save materials.
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02-09-2022, 03:06 AM
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#12
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Registered User
Join Date: Jun 2006
Location: Indianapolis, IN
Posts: 29
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There definitely is an engineering reason to cut different shaped holes: To remove as much material as possible and still maintain the structural integrity of the part. The size and placement of each size of hole is proportional to the size of each panel.
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03-11-2023, 01:23 PM
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#13
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Registered User
Join Date: Mar 2023
Location: Boone NC
Posts: 1
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Did the plugs today and don’t you know the first one I tried to put in I dropped !! Anyone have any idea where it goes and if it can be retrieved ? It’s def not down in the bottom anywhere
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03-12-2023, 03:54 AM
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#14
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Registered User
Join Date: Jun 2006
Location: Indianapolis, IN
Posts: 29
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I dropped a couple of plugs during the install. They fall down to the bottom of the blend door enclosure. They can be difficult to see, but to my recollection there is no “lower level of hell”. You should be able to retrieve it by hand. Try recording a video with your phone placed inside the vent enclosure to get a good view of everything. You can also get a cheap endoscope from Amazon:
Depstech Single camera endoscope
Having some RTV on your fingers helps keep it from getting away from you during insertion.
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03-14-2023, 05:52 PM
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#15
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Registered User
Join Date: Jul 2022
Location: DFW, Texas
Posts: 16
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Just ordered. And I have a camera and pinchers already in case I start dropping them.
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2003 Boxster S
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03-23-2023, 06:21 AM
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#16
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1998 Boxster Silver/Red
Join Date: Sep 2017
Location: 92262
Posts: 2,976
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Plugs? Lol.
The wheel already has been invented, and it's called tape.
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1998 Porsche Boxster
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03-23-2023, 07:00 AM
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#17
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Registered User
Join Date: Feb 2005
Location: It's a kind of magic.....
Posts: 6,419
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Quote:
Originally Posted by Starter986
Plugs? Lol.
The wheel already has been invented, and it's called tape.
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Plug are actually a bit slicker fix, and never seem to come loose as the tape sometimes does.....
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“Anything really new is invented only in one’s youth. Later, one becomes more experienced, more famous – and more stupid.” - Albert Einstein
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03-24-2023, 03:00 AM
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#18
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1998 Boxster Silver/Red
Join Date: Sep 2017
Location: 92262
Posts: 2,976
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Quote:
Originally Posted by JFP in PA
Plug are actually a bit slicker fix, and never seem to come loose as the tape sometimes does.....
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I used a 3M product designed for mitigating headlight/foglight chips. It comes pre-cut (I used it on a BMW) or in a sheet. I had both. It's ~1/8" thick with a nice adhesive. It's ne-ver coming off. No one ever will see it.
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1998 Porsche Boxster
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03-25-2023, 04:31 AM
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#19
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Registered User
Join Date: Jun 2006
Location: Indianapolis, IN
Posts: 29
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My blend door is waaay better than your blend door.
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03-25-2023, 04:38 AM
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#20
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1998 Boxster Silver/Red
Join Date: Sep 2017
Location: 92262
Posts: 2,976
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Quote:
Originally Posted by Carlton Bale
My blend door is waaay better than your blend door.
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Yeah... I'd have to see pics.
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1998 Porsche Boxster
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