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I am in the proccess of dissassembling the climate control system on my 66 chevelle. I am currently working on the cowl unit that houses the heater core & flapper doors. There is a lot of rust inside the cowl, and there is no way to take it apart. I beadblasted it, and got 99% of the rust out, but in the proccess I stripped away the foam that covered the flaper doors, I guess it keeps them from making a banging noise. What kind of foam can I use to restore the flap doors?, and how the hell do I get it in there? The old foam was stapled on. Can these doors be removed? I noticed that I might be able to pullout the pins that the doors swing on, but I want to see if anyone has done this so I don't destroy anything. Where can I get the correct shade of semi-gloss black to repaint this thing. I've tried all the Krylon's, Rustoleum's etc. that I heard about on this site, but they just don't look original. Is this a color I have to mix myself? I'll need the same color for the metal part of the dash, and tops of the doors.
 
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