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This video shows how to fix the “foam in vents” problem and repair both the HVAC blend doors using port plugs for a Porsche 911 (996 and 997) and Porsche Boxster/Cayman (986 and 987.)
Parts and Tools:
UPDATE: I just learned from the TDIclub.com forum that the person who was selling these plugs on Ebay passed away. The STL files are available on ThingVerse. You can use PrintAThing.com to 3-D print the STL file using ABS plastic.
printathing.co...
STL: thingiverse.co...
Former Source for plugs:
DSP Blend Door Foam Fix for VW Golf Jetta Beetle Passat: www.ebay.com/i...
Nashua 361-11 Foil Tape: amzn.to/3tnoxob
Permatex RTV: amzn.to/3rfe8bq
Milwaukee M12 Oscillating Tool: www.homedepot....