Before I put my heater/ac box back in I decided to clean it and replace the foam on the blend doors. I have scraped off the old (crumbling) foam and have removed the blend and vent doors. The doors have surface rust over a lot of surface so I am trying to decide what to do with them. I am thinking that there are three things to do with the rust. First, I could clean the old adhesive, wire brush, treat with rust converter and then put on the new self adhesive backed foam (extreme temperature rated). Second, I could sandblast them, powder coat them and apply the new foam. Third, I could sandblast them, put on about 3 coats of epoxy primer and then apply the new foam. I am thinking the paint route might cause paint odor when the heater is on. Anybody have any thoughts on the best way to do the restoration to avoid future rust????

 

Option #1 will work fine. Wire brush off the surface rust and paint it. I would replace the vacuum lines and vacuum actuators while in there. The heater/AC control switch that hisses a lot when going south might be worth replacing also. The newer 5th Gen Camaros have plenty of problems in this area and Blend Door USA was supposed to making repair pieces for earlier generations Camaros.