I was gonna use something other than the mopar kit you can get. I was just wondering if anybody had pics of what they used and the sizes? Thanks for the help guys!!!

 

Are you referring to the foam kit that seals the box against the firewall or foam that's inside the box itself?

 

Both!!

 

I bought the Mopar kit that seals against the firewall, so I recommend the same route if you can find it. For the foam around the heater core and evaporator, I used some expending weather-stripping foam from Home Depot that worked great. Let me see if I can find some pics on my computer, and I'll post them up.

If you end up trying to fabricate your own firewall seal kit, I'd recommend you go with closed-cell foam rather than open cell.

EDIT: Found some pics.

 

is that poly foam like 3/4 in size???

 

The stuff around the heater core? Yeah, it was something like that. It definitely had some give to it so it filled the gaps around the core very well.

 

Perfect timing. The heater core in my 98 sprung a leak 2 months ago so been running without a heater. Son is getting upset without heat now that it is cooling off. Already ordered the heater core (and AC evap core since it's the original int here). Expecting the Mopar foam kit this week and doing the job over Thanksgiving. Can't wait for the fun of taking out the dash. I've had just about every other part of an XJ apart besides the dash.

 

Do you just line the top and bottom of the heater core with the foam? What about the evap mine just came with no foam at all???