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I think we all want to know the answer to that question.

That's a great hack. Thanks for sharing.

I ended up just buying an assorted set off Amazon. I can't remember which one fit the best. But I left the link in the video description. K

I'm glad it worked out for you. Just check the cable once in awhile to make sure it's still cool and free of corrosion. I had a little corrosion on the cable on the fuse box side so i cut it back and attached a new copper lug and did a double heat shrink wrap on it to keep the moisture out. So far its working perfectly. Thanks for watching and the comment. Kelly

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@@deadlinekelly9938 Thank you!

You leave those connected. In fact you leave the old harness in place. Just disconnect the black thick cable that goes from the alternator to the fuse box and wrap the ends up with electrical tape and push them to the side. You don't have to remove the old harness at all. You just want the new cable to go from the alternator to the fuse box. I just used some zip ties to attach it to some hoses to keep it out of the way. Watch the video again and you will see what I mean. K

@@deadlinekelly9938 I made up a 3 foot long 4 gauge cable today, ran it from the alternator to the fuse box, and the wire doesn’t even get warm anymore. Everything works great thanks for the idea.

Awesome. Just check it once in awhile to make sure it's still cool. If it heats up it's probably some corrosion build up on the end. I had this happen and just trimmed the wire back a couple of inches and put a new connector on and really sealed it up good with the shrink wrap so no moisture can get into it now.

What switches are you talking about?

@@deadlinekelly9938 thanks again for contacting me... On the existing harness, there are a couple of electrical connections that come off the harness... How do they get picked up?

Ok I understand now. You leave those connected. In fact you leave the old harness in place. Just disconnect the black thick cable that goes from the alternator to the fuse box and wrap the ends up with electrical tape and push them to the side. You don't have to remove the old harness at all. You just want the new cable to go from the alternator to the fuse box. I just used some zip ties to attach it to some hoses to keep it out of the way. Watch the video again and you will see what I mean. K

@@deadlinekelly9938 deadline Kelly, thanks.... I'm going to give it a shot, this weekend...

De nada

Good to know. Mines still holding up fine so far.

That tape is pretty sticky and tough. I think by the time it might come off the car would have been dead and junked for some other reason a long time ago.

That's why I used it.

It's like they build them so you have to take them back to the dealer to get fixed.

Yeah. What were they thinking?

Yes. Resistance. Yes. Yes.

Where do I buy the copper not sure what they are called

@@rosaa.cedillo2285 Here are the links to the items I used for the fix. Cable - www.amazon.com/dp/B09QNM4PZT?ref_=cm_sw_r_apan_dp_T2K934283Q78ENKGNN0D&th=1 Copper Wire Lugs - www.amazon.com/dp/B09WVGLJ38?ref_=cm_sw_r_apan_dp_7KENA8E8SBZPG2GY05CQ&th=1 Fuse Box for 2004 VW Beetle - www.amazon.com/dp/B08Y8ZQSXT?ref_=cm_sw_r_apan_dp_RCW29F9V2G8JFG6T9NGZ

If you are having trouble directing the airflow to the vents you want it then absolutely this will help. That is one symptom that you have this problem. So if you for example direct the airflow to come out just the forward vents but you feel it coming out the defrost vent and the vent for your feet then you know for sure the blend doors are compromised.

Thanks for the info. I'm working on the next video and hope to have it out soon. I've just had so much work lately that it's been hard to find the time to do the editing. K

Thanks for watching and the comment. You can do it!

Ah don't be sad! Everything turned out great! It's still working perfectly and no one would ever know that anything was cut. For me this was the quickest and easiest way to fix the blend doors. Everything's great! Be happy 😊. Thanks for watching and the comment! K

Hey thanks for checking in. Yeah it's still working great. No leaks so far.

I put abottle in back in March or April and I've got a leak , but the level on reservoir in engine compartment has not changed since I put the k seal in

Glad it worked out for you. I tried to do it the simplest way possible. But I'm happy you got yours fixed too.

I think they just want you to have to take it back to a dealer to be fixed. But you can fix it yourself for just a few dollars and some patience.

@@deadlinekelly9938 I read a theory saying the holes are there for the reason of making the blend doors easier to move. One factor would be simple weight reduction and the other is more technical. While the fan motor is running on a high level, the rush of air creates a force making it harder to move the blend doors. The holes with the original sponge-like coating would allow for _some_ air to pass through them, resulting in less air resistance.

That's awesome. I'm glad it worked out for you. Yeah it looks a little scary but you can do it!

Thanks for the advice. I'll look at dismantling them a d using wd40 on them. Been so busy bit I'm ready to get back on this project.

Thanks for watching. Are you talking about the plastic ac components or your interior plastics in general?

Try wire brushing the copper and also use a little baking soda and water to remove any corrosion.

I already cut the wires, replaced the lugs with new copper ones seems to be working well for now, the alternator wire doesn't heat up anymore.@@deadlinekelly9938

I bought mine for $900 and it had 85k miles. Over 200k I think you are looking at the lifespan for this car. I would keep looking for something with lower miles.

Why not?

to each their own. I’m going to do it to mine! The car isn’t worth the labor to remove the dash structure to do the exact same thing. It’s called value, pick your battles man

Hi again Larry. Thanks for the info. I have another video shot but I need to finish the editing. Thanks for watching.

Hi. This is the wire I bought from Amazon. 4 AWG Gauge Fully Assembled Battery Cables, 1-15ft Lengths, Positive or Negative Wire, Pure Copper Battery Replacement Cables, Solar Car Truck RV Camper (4ft, Single Black, 3/8” Lugs) www.amazon.com/dp/B09QNM4PZT?ref_=cm_sw_r_apan_dp_PQ9W0ZEJHP9GGJQ951MY&language=en-US

The cable I used is $21 on Amazon. See the link in the description.

Do you a number cause I do not know which one

Yeah it's a problem.

Yeah just try it. It is still working on my VW and that was about a year ago that I tried it. I hope it works out for you. Thanks for watching. Kelly

Hello my friend. I think you meant to say duct tape. And I don't think any part of this fix can be made with duct tape. Thanks, Kelly

I hope it works out for you. Mine is still holding up and no leaks so far.

Thanks for watching and the comment. I'm glad you checked out the video. I'm not a mechanic but I was able to take my time over a long weekend and get this done. You can do it I'm sure especially if you have worked on your son's car before. Let me know if you have any questions. Thanks for watching and the compliment! Kelly

Hi and thanks for watching and for the question. So I haven't heard of anyone having an issue with the 3 pin connection but I would think that the problem you are having is caused by the same thing which is too much resistance entering the fuse box. I would just do the fix like I did and just keep checking the temperature of all the wires and the 3 pin connector. Drive it around the block a couple of times and check the wires to make sure they are not heating up too much. Let me know how everything goes. Kelly

I totally agree that they want you to bring it in to the dealership so they can charge you an arm and leg to fix this problem. So fix it yourself and save some money!

@@deadlinekelly9938 you just don't save time! 🤣 But it's fun!

For sure my friend!

Thanks for watching. The glue is J-B Weld Plastic Bonder. You can find it at Lowes, Home Depot, or Amazon. It is very hard when it dries. You need to look at fixing the Blend Doors if you have black foam particles coming out of your vents when you turn the AC on. Those particles are the foam covering of the Blend Doors. Also if you turn the AC on and select, for example, the setting for floor only vents and you can still feel air blowing out of the upper vents then you probably need to look at the Blend Doors. Finally, you might be able to cut a smaller hole in the bottom section but remember you have to be able to get your hand in there holding a section of tape and be able to move around enough to get the tape into the correct spots. You don't want to miss a section or accidentally tape the door closed so it doesn't work at all. Also you need to be able to clean the Blend Doors before you add the tape. For me it was easier to go ahead and just cut that larger section out and glue it back in after I was done. I did only as much as I had to do to make this fix work. BTW it is Still Working Perfectly 8 months later. Hope this helps. Kelly

Hi Thank you very much for your reply. I could not have even thought of doing this process, at all, were it not for watching your video. My old Beetle is getting on and I am trying to keep it on the road. I have proceeded with cutting a section, as I mentioned, and it came out using the vibrating saw that you used. My vehicle has over 292K Kilometers (182K Miles). I live in Canada, specifically British Columbia. The body is like new and has the original paint job. I was having an issue with my AC and not sure just whether these blending doors were working properly, before I looked at the other components of the AC. I cut a section about 6" by 4" and was able to view (and access) the doors. I essentially cut along the top of the bottom section where it thickened and then about 1/2" in from each side. That meant I only cut three sides. I will use similar plastic, as edge backers, and glue them in place. Once they are solid I will put the cutout back and glue it against the backers. (Thanks for identifying the glue.) The doors were working and pristine. Yes the foam was all intact and covered both doors completely. I could hardly see the holes through the foam. I was wondering if the fact that my Beetle has always been driven in colder climates and possibly survived because of that. Anyway it is going back together and I am so pleased for your help. Cheers ...

I'm glad it all worked out for you. I live in central California and we use the ac every day so maybe that's why the blend door covering wore out faster. Anyway thanks and have fun with your beetle. K

Hey that's great. Thanks for watching. I'll be posting another video soon. Did you get the exact same bike? K

Thanks for watching and the comment. Let me know if you have any questions and also let me know how everything goes with the repair. Kelly

Yeah I would have to see that to understand how that would work. In my year/model there is a wiring harness, airbag components and metal piller all in the way on the passenger side.

Thanks for watching and the comment. Ok well when you remove the center console section about 19 minutes into the video you still don't have access to the blend doors. You have to cut through the section under that before you see the blend doors. See about 57 minutes into the video and you will understand why I had to cut out that section. Thanks, Kelly

I do get the cutting out for accessing the doors. But, wouldn't that be possible without removing all of the additional components on the passenger and driver sides?

No.

Ok - I'll go with that. @@deadlinekelly9938

Be sure to check this. If the wires going into the fuse box are too hot to touch then you need to do this fix. If you make the fix before the fuse box melts then that will save you money also because you won't have to buy a new fuse box. Thanks for watching and commenting. Kelly

@@deadlinekelly9938agreed. ​​⁠excellent advice. I’d wax glue a short piece of birthday candle at the terminal for a few days to determine the severity and go from there. The most current hungry parts are - 4 glow plugs, day time head lights 2, radiator fan and ac fan on asphalt in a traffic jam in summer.

Thanks for watching. So far I have found parts on Amazon and Ebay. If you get a chance to watch more of the series you will see the stuff I am buying. I'm still working on my project so be sure to subscribe! Thanks again, Kelly

Thanks for watching. This was the easiest way to do it and it worked out great for me.

👌

Thanks for watching. Yeah I did recently purchase a set of JIS screwdrivers for the restoration. I'll show them off in the next video that's coming out soon.