Originally Posted by GregBBRD

Actuation rod #48 controls the flap that separates the heater from the A/C and generally can be adjusted some to shut off the heat, even with the foam missing. Be careful not to over adjust this rod, as the lever it attaches to can (and does) break. That lever is part of the HVAC box....not a separate part. (Someones needs to "print" some sturdy replacements.....for the 1-2 we find broken every year.....another in a long line of "extremely low volume, never make back the time it takes to make them" 928 parts.)

Thanks, Rob, for the foam pictures.

BTW....The "clue" for deteriorating foam is turning your HVAC on high....those "chunks" that come flying out are the old foam.

Originally Posted by The Forgotten On

If someone used a high res laser 3D scanner it could be prototyped pretty quickly with thicker, stronger material.

Originally Posted by GregBBRD

Yes. And Rob Edwards has one.

My point was that the investment in time, equipment, and actually making a tiny run of pieces, like these, isn't profitable.