When I did the flap seals in the box  I used the most compliant foam I
could find. Open cell, thin, as close to the stock type as I could
find. I did try closed cell foam but I found that the flaps did not
close as easily as I thought the should.

alistair

On 20-Apr-11, at 1:48 PM, Michael Hart wrote:

> James,
> I used MD brand 'camper self-adhesive foam tape' from HomeDepot
> (this is 1.25"
> wide and 0.25" thick, self adhesive on one side), applied after
> completely
> removing the residual flecks of original foam (& I took a lot of
> time to be sure
> this was applied carefully...). I sealed the two halves of the
> heater box back
> together with silicone tub caulk/sealant & the proper metal clips.
> I'm pretty
> sure the whistling is coming from the heater box not the doors or
> windows, as it
> goes away when you open the heater vents, so you could perhaps say
> that the
> products I used were not good enough (or probably more appropriate
> to say the
> application was not good enough??). It will take some time before I
> pluck up
> enough courage to re-open the dash to investigate further.