I have to replace my heater core (doing evaporator while in there). I should have just replaced it when I had it out before but my Dad convinced me not to. Here is my dilemma I need new drain hole, heater tubes, and AC tubes, seal. They seal them up against the firewall. I have two options
1. Order the heater tubes and drain hole seals from Mopar, which delays me getting it back together.
2. Build my own (have to for the heater tubes and they don't make it anymore) I bought these before when I resealed the HVAC doors. Only issue is I need a waterproof foam and it has to be thick (my memory tells me the ones I ordered were over 1" thick). I would like it to have adhesive backed but can use spray foam.

Anybody have any ideas for #2? I know a member here rebuilt his box before.

P.S. Sorry for being MIA college, life, and my other vehicles took over and haven't really messed with any of my second gens until now lol

 

In this area, we have a place that stocks all types of foam and cuts it to size. I'm sure that they would have what you need. When I typically visit them and show them a sample of what I'm looking for, they typically have it available. Do you have any of these types of places in your area?

https://www.foamtosize.com/

 

I didn't see sponge rubber there. I know you can get the factory replacement foam somewhere(door seals) but why put the same thing in that disintegrated in a few years? Closed cell sponge rubber is what you want for both the inside door seals and the outside gaskets.

 

Unfortunately not

 

I used blend door foam for the inside, ink taking about the gaskets that seal the box to the firewall. I know high density closed cell foam is waterproof but i can't find anything thick enough. I might just bite the bullet and order the factory ones and wait the 2 weeks. I circled what I'm after in the picture (I know they are for a 3rd gen but I wonder if these would work)

 

Don't know what you have back east, but Ross/TJMaxx or your chain sporting goods store, i.e., Bob Ward's sell 'yoga' mats in closed cell foam up to 1 in thick. I have a couple I bought for various things. Can double them up with that same spray '77' for any application, I'd guess.

 

This thread has what I used.
https://dodgeforum.com/forum/2nd-gen...vac-seals.html

Posts 2 & 8

 

I over engineer lol I don't want any water intrusion
Thanks!