Blend door repair, removing the dash
 

When attempting to rehab foam on the blend doors, has anyone just removed the entire dash to access the blend doors? It seems harder initially but less cutting, etc. It might be faster than cutting and repairing the duct.

Just curious as that's the approach I'm taking this weekend. My Boxster is already out of commission while I await o-rings for the oil cooler + vacuum hoses and fittings for the SAI system.

http://986forum.com/forums/uploads02...1709738771.jpg

This image was borrowed from AAZCD-Jon on the grassroots motorsports forum. If Jon sees this, I'll return your image when I get my Boxster back together. ;)

Read this whole thread: https://986forum.com/forums/performance-technical-chat/42802-interior-vent-debris.html

I don't think that Meir's PDFs are on dropbox anymore, but I've got them stashed on a computer if he doesn't have them online somewhere.

I still prefer the 'behind the radio' method. Removing the dash is a lot of work and the plastic trim are likely to be very brittle and ready to crack.

I just confirmed that Meir's links in this thread are all working: https://986forum.com/forums/diy-project-guides/37246-c-evaporator-replacement-c-foam-flakes.html#post548591

Thanks again Meir for being awesome. :cheers:

I removed the dash as I also needed to replace the recirculating flap servo. When I had the box out, I was able to spot and repair some rust forming on the bulkhead panel the fresh air enters through.

I feel taking the HVAC suitcase apart to patch the doors the more thorough option. I covered both sides of the doors in aluminum tape, then adhered thin neoprene sheet to that with contact cement. Trim to fit, presto. :)

You must have a lot of patience. :cheers:

Do you have any pics of your dash out? You removed the steering wheel... the entire dash... the entire shebang?

How much time did it consume, all in?

Bravo.

I need to dig it up, and should have them posted this weekend.

I don’t recall it taking a terribly long time to pull the whole thing out. Maybe 2-3 hours?

I've just accepted the occasional 25 year old bit of foam flying out from one of my vents....lol. Actually I've gotten pretty good at using a long tweezers to pick any pieces stuck in a vent. As a 100% summer sunny day driver I don't care about "blending"...or for that matter heat or AC either. I'm sure most of the foam has already flown out.