Thank you Jorrit for sharing your excellent write up on the blender doors fix. I downloaded your PDF and decided to give your “3rd way" a go using the 3d printed parts and Reinzosil as the sealant/adhesive..

I have a 2000 Eurovan Camper with 140k miles. The blender door foam starting blowing out of the vents a couple of years ago and now my AC isn’t as cold so I was motivated to make the repair. ?

Once I had the dash apart I practiced installing the pieces, as Jorrit suggests, with them siliconed to my finger. ?I realized after a few dry runs that there was no way I could do this. I could reach some of the holes but I was not coordinated enough and I was physically unable to reach at least two of the holes that needed to be filled. Longer fingers and skinnier arms sure would have been helpful :-)

After feeling defeated I started to noodle on another way to install the plastic pieces using some sort of rod to reach the holes. Through the dash I could see both blender doors and all holes that needed filling, or at least part of each hole. I used a headlamp placed in the radio slot and AC/Heater control slot so I could see what I was doing. I used a clamp on the cables that actuate the blender doors to lock them in a position/angle that was helpful.. In the slot where the radio was, I had to bend the “L” bracket that held the radio antenna, down and out of the way in order to reach the blender doors. The bracket was fairly easy to bend down by hand and then back up after I was finished.

Then I used a piece of 1/8” cold rolled steel rod 22” long with a loop on one end and two bends on the other end. I was able to carefully fish the rod through the dash and reach every hole that needed filling. The rod was stiff enough that I could apply some pressure to make sure each piece was pushed all the way in and snug. The loop at one end of the rod allowed me to precisely control rolling the rod and the two different angled "bends" were each used to temporarily glue (with silicone) the plastic bits to. The small bend on the very end of the rod allowed me to reach the most difficult to reach small holes on the left side of the rear blender door. (See photo) The very top hole and bottom hole on that section were the hardest to reach/install. I had to adjust the door slightly open in order to reach both of those. The other bend in the rod angle was used to install all of the other plastic pieces...I also put a slight bow in the overall length of the rod so I could reach every hole. I’m attaching a photo of the rod I used..

I used quit a bit of the silicone to glue each piece to the rod to avoid dropping them. ?After I pressed the pieces into the blender doors I used the end of the rod to scrap off as much of the excess silicone as I could. ?I did managed to drop two of the pieces during the installation but I was able to retrieve them using a vacuum cleaner that had a 1/2” x 24” plastic irrigation tube taped to the end. The vacuum modification was also key to being able reach and remove all of the old foam that was left on the blender doors. I probably spent just as much time cleaning the old foam off of the blender doors as I did gluing in the new plastic pieces. ?

I hope this helps!

David