Clever approach 78F350! Thanks for documenting.


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Awesome job 78F350 - thanks for the write up!

Great work 78F350. I have needed to do this job for the past 2 years also and have been studying the excellent write-up that Meir had done. I do not even pretend to a mechanic but I have done simple jobs such as replacing a radiator, brakes, alternator, starter ect.. on my other cars. For some reason I have been scared to get tools anywhere near my 99 Boxster. The only thing I have attempted so far is re-soldering the micro-switch on the top latch and I recently replaced the top assembly so I could have a glass rear window. Both of those went fairly successfully.

I was going to attempt the frunk entry repair method next weekend but I am still very nervous about my ability to pull it off successfully. Now this morning I see you have presented another possible solution.

I am hoping I can have some more details and opinions was to how to tackle this job.

1. How difficult is it to remove the front dash console?
2. What would I have to modify to the console area to gain access to this. (I replaced the radio in the car about 5 years ago but I do not remember what it looked like inside there).
3. What did you use to cut the vent and how likely is it I would damage other parts when I tried to cut into it.
4. Why kind of tape did you use to seal everything back up as I know heat can loosen adhesive over time.

Thanks for any advice that anyone can share.

William

1. On my car it was very easy to remove and access. The switch panels on the side are removed to access screws that hold it in. The console changed in the later years to one piece and I'm not sure if it's more difficult.
The location of climate control unit, cup holders, and type of stereo may effect the difficulty.
http://986forum.com/forums/uploads02...1479411951.jpg

2. I didn't have to make any modifications. I just disconnected and moved things that were in the way. If you replaced the radio before, it's very similar.

3. I used an oscillating multi-tool with a cutting blade. Surprisingly easy and precise. I almost used a Dremel, but came across this first. Either should work well.

http://986forum.com/forums/uploads02...1479412239.jpg

4. My one concern after completing the job is that I'm not sure how well it will hold up to heat long term. You may want to look at 3M Flue Tape which is good to 600 F. The tape I used is thicker than most and has a very strong, finely woven cloth layer. When I tried to find specs online, it looks like it has a recommended operating temp up to 200 F which may be close to the peak temps.

Thank you so much for your quick reply on this. Luckily I have that tool and some flue tape in my garage. Now I just need to find the courage to give this a try.

I may reach out again if I run into any issues.

Hopefully this becomes another alternative fix to a common problem.

78F350: Freaking awesome!

I just did this. When I opened up the console and all my foam was gone. I used a standard cutting blade to make the cuts on the vent. I used masking tape to tape up the holes. Took me totally 15 minutes in total. It was very easy to tape the vents with my hands. I did not need to use any tools

Thanks for the innovative process :)

Has anyone else followed this method? I need to fix the foam in my vents and this seems like the easiest method.

Posting this here for posterity.
 

Yes. I split the upper duct at the seam, though.
It was a pain getting all of the old foam and its backing material out, and getting the flaps covered, but a lot easier and more thorough than the other method that requires removal of the heater core and does not address the other flap.

Forum will only let me upload one picture at a time. :rolleyes:

And one more showing the piece of duct remove during the repair.

I am not getting cold air. Freon ok. Would this problem cause AC air not to work too?

FYI... i did this fix using this write up last winter. Worked like a charm. Had a great summer with no foam blowing in my face.

no.
The missing foam just effect the heater efficiency.
If you are not loosing Freon and still have no ac, you have another issue.
Start by testing the compressor.

Meir makes an important point for some who are reluctant to attempt this repair. Foam loss only reduces cabin-heater performance .It does not seem to affect a/c performance. So in a really mild/warm climate - just ignore the foam debris ?

That's what I've done, foam stopped coming out after about a year (mostly), and it doesn't seem to have affected the cold (or even the hot too much, but we never see freezing here so...)

If you like to keep a clean interior then this is enough motivation to fix this. Turn the car on and get some of this foam in the eye a few times and that’s the rest of the motivation anyone will need.

Not so much in Texas. Before the foam repair I had to run the a.c. at max recirculation and even then it took fifteen minutes to stop sweating in the car. After the repair the AC rocks. Normal mode is satisfactory for a 100 degree day.

There is some misleading info here.
The deteriorated foam absolutely will affect both heat and AC, as James pointed out. The flap in front of the heater core, which is always hot, either makes air blow over the core for heat, or blocks it off. If that flap is full of holes, your AC will partially blow over that hot heater core.

Also, as Tom said, it's nice to keep a clean interior and not be pummeled with foam bits that turn to black tar when you touch them. :D

Well, I can speak only from my experience.
The Boxster S I had, had a leaking evaporator, so the AC didn’t work regardless, and when I fixed it, I obviusely re-foamed the flaps.
On my 99 box and 02 996, there was/is no foam coming out anymore. So the flaps are naked for sure. I do not see any difference with the AC between the 3 cars. They are all blowing cold. The heater is a different story.
With that said, I do not like penguins temperature in my car, although i leave in FL. :D
Since I have the Boxster S (with the fixed flaps) and the 996 both in my garage, it will be interesting to preform a comparison between the two, using an infra red thermometer directed to the center AC vent (as described in the shop manual).
Maybe I’ll do it next week when I get back from my road trip.

Through two summers of ownership my Boxster spit enough foam to make heater barely working... so finally did this center vent surgery.

With small hand though the cut out, both flaps were fairly accessible to tape up the holes, while positioning and pressing multiple tapes were a bit tedious. I used aluminum waterproof tape that seems solid and sticky enough for the job.

Now heat is back and I also know why AC was often too cold as little heat blends with chilled air. What an ingenious repair method!!!

Thank you.

Even though I'm in NW FL, the weather has been unseasonably cold the last few days, with lows in the 20's and high in the ~40 degree range, I know lots of folks have it much worse.

I've lived with crappy heat in the car for many years. I just put up with it as the car is not a daily driver anymore (retirement) and we just don't have many extended cold snaps. Usually, we'd get a cold snap, i'd think about this repair and then procrastinate and put it off for no good reason.

With holiday company gone, I decided this afternoon to find this thread and seal up the holes in the deflection panels. I've replaced my radio and had my dash and console parts apart in the past so I wasn't too worried about completing the repair.

Needless to say, I was blown away with the 'after' heat performance...simply night and day difference. I followed 87F350's direction and was able to duct tape all the holes. I was even able to reach the two inner panels without too much difficulty. I can't claim all my tape pieces are perfect and without wrinkles but all the holes are covered and the ductwork is taped back up and looks no worse for wear (thank you black duct tape).

Should have done this years ago! BTW, there was no sign of foam on any of the panels anymore...
Thanks again for the great write up!

Here in Houston where it has been 31 F and 26 F in the morning respectively. GIVE ME HEAT! Oy Vey! After doing the full up fanatical Meir repair for the AC, I ALSO HAVE HEAT! I agree, so nice to have actual heat when it's freezing!

So glad that I taped up my blend doors with more holes than Swiss cheese. It has been brutally cold here, down to -5F, but the heater keeps cabin warm and comfy!!! Great winter driver actually, with a set of snow tires and a hardtop!

Mine blows the same flakes and not so hot air when using heater. The current random cold weather has me wishing it did blow way hotter.

I'll look into fixing it soon.

When the blower box is in Swiss cheese mode the heat doesn’t really work. But, when the blower box is correct the freakin’ heat in these things is a blast furnace. Very nice for those super chilly days. I’m getting foam, but haven’t lost enough yet to do the fix.

Question for the collective.....
 

....Does this foam deterioration affect ALL 986 model years, or did they make a running change in say....2003, for example, to fix the issue?

...all 986 and beyond: Cayman foam being blown out of the vents

Mine started doing this last year, I thought it was just a filter causing it. So something new to add to the fix list. :mad:

Foam drain trays and foam covered heater flaps, what was Porsche thinking? Why not at least plastic? Can't be that much difference in weight.

Probably sound attenuation?

Was chatting with a friend who has an old ferrari and does quite a bit of wrenching. He suggested spraying some clear paint into the vent hole before it gets to bad to strengthen the foam bond as a temp fix. Not sure it would work, the idea sounds plausible.

That sounds awful. Smelly and could cause moving parts to bind or lock up. Just fix it right. ;)

Yeah was pretty much my thought on that idea as well. That's why he is driving an Italian car and not a German car! Haha

That guy sounds like a nutbar! :p :D

He is actually a pretty good mechanic, just some of his ideas kinda seem strange. He is our entomlogist. He Used to be a guzzi mechanic, likes to tinker on voltswagen buses, has an old gts ferrari i think it is its the one from that old tv show. I drove it, definately too small for me. Anyway he likes everything stock as possible. Good guy but you really have to talk to him will make you laugh.

Need Better Taping Ideas Please
I did this repair last Fall and must have a stuck blend door now. Before I dig back into the dash, I am looking for a better option for taping up the holes in the doors. Like most of you, I used multiple pieces of strong duck tape. Hard to get the tape lined up and stuck to the doors.

I think a better solution would be cut ONE piece of tape the width of the door, something with a removable sticky back. That way you can place the tape inside, stick an edge and peel off the removable backing. Ideas?

What about some dynamat? Sticky on one side, and kid of rubberyish. Could trim to exact fit.

Good idea. Would it be too think or heavy for the doors to operate property?

Do know wouldnt think so small square.

I used aluminum tape with waterproof adhesive, sold at Home Depot. Very sticky and easy to work with, used several horizontal strips to cover top to bottom of the doors. I think one big piece would be very difficult to place it, unless the whole HVAC assay is torn apart.