I just went through the same exact thing on my '96 VW
GTI back in February.

What I used was a product called Fun Foam, available
at your local craft store (I got mine at Michael's).
I cut the foam to size and used weather strip adhesive
(it was in an orange tube) to glue it onto the blend
doors.  I got this idea from vwvortex.com and it has
been working great.

Ryan

--- roger sisler <rogersisler2000@YAHOO.COM> wrote:

> I cant find anything that will work . I went to Home
> Depot and went to the weather strip asle. The have
> lots of weather striping. All about 1 inch is width.
> I need 2.5 inches for the flaps.Also, the foam I am
> removing has a sort of "skin" on each side of the
> 1/4 inch thick foam. This, for wear resisrtance, and
> a better seal? The foam is very soft.I understand
> that it has a softness rating of 1(whatever that
> means). I looked in the archives and have found
> several request for a good foam lead. Nobody got
> one,so I dont know what they used, or if it lasted.
> The heater box replacement requires the removal of
> the dash board, so I want to do it right the first
> time. These flaps on the early box have no access
> for removal unless the entire box is removed.Not
> good, and VW changed this on the later boxes. I want
> this early box because it has the oval cut out for
> the BA6. So ,what did you use for the foam gaskets,
> and how long have they lasted? Thanks,Roger
>
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