To clarify: The "seals" between the defroster output flanges and the defroster plate holding the interior, corrugated ones are plastic tubes. The "noodles" replace those, and if you trim the I.D. correctly they seal well. The rest of the seals around all the plates and the heater box are thin and I used a bicycle innertube cut into appropriate widths, holes made with a hole punch, to fit the application. The foam ring between the engine bay part (the one with the screen) and the interior box (4" DIA) I used closed cell "packing foam" sheet, three layers, cut with a compass cutting tool and joined in layers with CG "Ply-o-Bond" cement...a thin film of RTV would work as well. The idea is that the commercially available "seals" are foam which can absorb water, while the materials I've adapted do not... NO MORE RUST is my primary goal here. Same packing foam as the exterior box seal was used to seal the fresh air flap in the interior, BTW. /ubbthreads/images/graemlins/hammer.gif
HTH!
MacGyver is my middle name...