Frunk HVAC plumbing cover restoration

[WMichelsen]

Has anyone successfully restored/reformed the cardboard hvac plumbing cover in the frunk (911-551-067-05). Mine, and most others I see, are a bit un-curved in the middle. It seems like it might be possible to steam/moisten it, and re-form/re-curve it. I'm wondering about other's experiences trying.

I've searched, and I've seen threads about re-making them with aluminum sheet or fiberglass. But, I'm more interested in just tightening the shape of mine. Then maybe a shot of paint.

[fallingat120mph]

Originally Posted by WMichelsen

Has anyone successfully restored/reformed the cardboard hvac plumbing cover in the frunk (911-551-067-05). Mine, and most others I see, are a bit un-curved in the middle. It seems like it might be possible to steam/moisten it, and re-form/re-curve it. I'm wondering about other's experiences trying.

I've searched, and I've seen threads about re-making them with aluminum sheet or fiberglass. But, I'm more interested in just tightening the shape of mine. Then maybe a shot of paint.

As I do my rebuild I have been wondering the same.

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Erik

[eastbay]

I've reshaped these along with door pockets. You have to soak them most of the way through to be able to bend them into shape. That's the easy part.

The hard part is figuring-building a buck to clamp the piece to while it dries. Straight pieces are easy though.

[smadsen]

I straightened my door pockets with a spritz bottle of water and a steamer. The secret is having a mold or clamps to hold it in place while it dries. In the case of the door pockets, a piece of aluminum angle clamped in did the trick.

I think I'd soak/steam your piece and work it until all four bolts are where they belong, then let it dry for a few days.

[WMichelsen]

I agree with these notions. Establishing the backing form seems to be the hurdle.
I can't get to it for a little while. But, since it's been done, I'll give it a try later.

[EC900]

Since this is basically paper cardboard, even if you were able to straighten it up by steam or water it’s only a matter of time (and humidity) it will warp again.

Unless you want to epoxy aluminum strips to the back sides to allow it to become more rigid, there’s no guarantee the bond will hold up to the paper substrate. Glue, clamp and let each section to harden all at once or one section might snap under tension from clamping the next section.
I’m not sure the radius of the curve but green pvc sewer drain is 6-1/4” and can be used as a backer to hold a curved section, if you cut it can be heated and opened up and shaped to a larger curved form.

I refurbished mine by prime/paint, the area around the brake fluid reservoir was damaged from fluid leaks. I was able to lightly sand down and primer the entire piece for uniform surface, then topcoat with satin black lacquer. No primer and any paint will look blotchy as it soaks into the paper unevenly.
You have to be careful not to soak paint into the paper edges which will cause it to swell and separate, so flash coat oil based primer, let it dry, sand (not edges) and repeat.
I used lacquer because it’s fast drying and can be re-coated in minutes for uniformity.
The results look good, not perfect, but a lot better though I have the snap in OEM felt type trunk liner and it’s always covered anyway.

[rokemester]

Another thing that links Porsches and VWs. The use of paperboard, cardboard or whatever board in the frunks. I guess plastic injected parts were not available or cost effective in the 60s 70s and 80s

[Matt_911]

I just remade mine - I used 3mm MDF. Traced from the original. I soaked it in the bath for about 6 hours, clamped it over the original one with the metal brackets with lots of clamps and bulldog clips, and let it dry. Then coated it with PVA glue and painted it black. Came out perfectly.

[Matt_911]

https://imgur.com/a/HGchQ41

Picture of same

[faverymi]

I covered it with new trunk carpet kit.

Isn't that the way it should be?

[Showdown]

I do this at work all the time but with paintings on board.

The use of a buck is key

You can wet or steam it but using a mix of water/pva will strengthen it when it dries.


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