DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
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THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHDIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Leading reported evidence
Use 3m product designed
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
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Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed
I used a 3M product designed for mitigating headlight/foglight chips.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Frequently discussed work
Repair option
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
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Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Read full discussion summary
Leading evidence: 'Use 3m product designed' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Repair option' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Repair plugs (fix foam coming out of vents)
Suggestion or failed attempt
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion · Original poster
Porsche 911 Boxster Blend Door Repair Plugs (fix foam coming out of vents)
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Set …and they fit
Suggestion or failed attempt
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion · Original poster
The size and number of those plugs looked very similar to the Porsche blend doors, so I ordered as set…and they fit!
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use clear rtv sealant
Suggestion or failed attempt
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
I'm planning to use clear RTV sealant for a neater appearance.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Frequently discussed actions (10)
These are separate views of the same evidence. Frequency alone does not establish a fix, and these counts must not be added together.
Repair option
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Repair plugs (fix foam coming out of vents)
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion · Original poster
Porsche 911 Boxster Blend Door Repair Plugs (fix foam coming out of vents)
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Set …and they fit
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion · Original poster
The size and number of those plugs looked very similar to the Porsche blend doors, so I ordered as set…and they fit!
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use 3m product designed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed
I used a 3M product designed for mitigating headlight/foglight chips.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use clear rtv sealant
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
I'm planning to use clear RTV sealant for a neater appearance.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use fiberglass three times
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
I've done that repair using fiberglass three times.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use of the tape
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
It is an HVAC *duct*, so ...correct use of the tape.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use plastic plugs
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion · Original poster
Some users have started using plastic plugs to block the holes in the blend doors.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use some commercial 3d printing solution like shapeways
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Or you can use some commercial 3D printing solution like shapeways.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use tapatalk
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
DIY: Repair HVAC Blend Doors using Plastic Plugs (i.e. fix for foam in air vents) - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Coverage and how to read this overview
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
23 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
986Forum: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
0 acknowledgements have no verified action link; they do not establish a repair result.
Generation: 20261026T124918Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
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
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.
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.
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!
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.)
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.
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.
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
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.
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.
Here's an stl
I found on thingiverse if you or somebody you know can print ABS or PETG.
Or you can use some commercial 3D printing solution like shapeways.
I've not tried these myself but I will later this summer.
This is a source reference. Confirm exact model applicability in the original material.
