JD, I echo all the accolades that the others have offered.? Thank you for your post, and I need to do this, too.? Two comments- the first is that I thought that the? "best" repair to this is something that is like foam-? very light weight, but also would last a long time, preferably forever.? I think that the door was meant to be very lightweight so that it can move rapidly.? This would be most evident during a defrost cycle- the system is sending heated dry air to the windshield using both the heater and the air conditioner.? Of course I am speculating about this- don't know how this door moves- only VW knows.? You would have to have some days/weeks of how this works in order to know-? and you may not notice anything except that it now works like it should, or better than it did.? Any repair that works is all good, so we say.? Still with the first comment- are these things lightweight in what you would consider "foam" so that we would choose this instead of another thing- like duct tape?? Got an opinion on that?
Second comment-? the comment about replacing the heater core is troublesome to me in that if you have used the VW coolant you can be reasonably sure that the heater core is not deteriorating, or rusting internally.? Even other coolants are good for this prevention.? If maintenance has been done correctly, this should not be a problem.? Still, if you notice what you think is rust in the coolant, you should also look at your radiator as another suspect.? Generally, the OEM radiators are very reliable.? As was stated earlier, removing the heater core is much more work, so maybe looking at the coolant for indicators is a consideration.
HTH,? Mike
