Date:         Tue, 12 Jan 1999 08:14:24 -0700
Reply-To:     John-Reed Maffeo <rlpa80@EMAIL.SPS.MOT.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
Comments:     ( Received on motgate2.mot.com from client mothost.mot.com,
              sender rlpa80@email.sps.mot.com )
From:         John-Reed Maffeo <rlpa80@EMAIL.SPS.MOT.COM>
Subject:      Re: COLD fresh air leaking
Comments: To: Vanagon Mailing List <Vanagon@vanagon.com>
Comments: cc: jjvantol@USWEST.NET
Content-Type: text/plain; charset=us-ascii

>    From: Joshua Van Tol <jjvantol@USWEST.NET>

--- snip
> The sealing foam falls off the control doors. On my '85, the foam has
> fallen off of 3 of the 4 flaps in the enclosure. I tried replacing it with
> the closed cell that's used to line tool boxes, but it's too stiff, and
> doesn't seal well. The only way to get a replacement from VW is to buy the
> whole flaps at ~ $90 each.
>
> If any list members or vendors know of a good substitute, or, better yet,
> have some to sell, I'd be very interested!

I have had success with opencell foam that I purchased a a FLMHS
(Friendly Local Mega
Hardware Store). It was sold in the airconditioning/venilation section.
The vehicle I
installed it on was not a Vanagon, but rather a Jeep Wagoneer, but the
procedure should
be similar once you disassemble things down to the flap itself.

1. Remove all of the old foam and adhesive. Rust removal as necessary.
Prime and
        paint if desired.

2. Cut out a piece of foam the exact size you need to cover the flap.

3. Put a thin layer of contact cement on the metal flap and wait until
it
        is tacky.

4. Gently (very gently) lay the foam into position. Do not press down on
it with
        your fingers. If you do the foam will not rebound because it will be
stuck
        to the adhesive. If you need to press down use a large piece of thick
cardboard.
        Press lightly.

5. If you mess up. Start over at 1. above ;)