Originally Posted by Gkayaker

Spent most of today with the Crossfire and wanted to share thanks and updates:
zip439 -- You were right on target re over application of sealant. Almost like surgery to separate the gasket from the sealant at various points totaling about half the length.
Onehundred80 -- Knowing that the gasket was supposed to move freely and held in place only by cowl cover gave me the confidence to pull on the rubber and cut the sealant.
M60A3Driver -- Followed your steps re hot soapy water, cleaned grove thoroughly with toothbrush, picked and peeled off sealant with putty knife and fingernails. Managed to remove 98% of sealant, will have another go on one spot that will show on top edge. Kinks have eased out to where I should be able to put it in place, may need a couple dabs of adhesive to hold it while positioning the cowl.

New problem is that the windshield is now not 100% sealed along bottom edge. Putty knife easily slides past sealant at location of VIN tag, maybe others. Based on what I have learned this far, I'm reluctant to take it to a glass shop. Existing sealant is black, but what is the material?

Re the Flapper Door, turns out it wasn't cork, just some kind of backing material for what seems to be disintegrated foam. Cleaned off the balance of crumbly foam with a brush and my fingers, don't think a little air leak will be a problem. Vacuumed everything again, blew out the air ducts, replaced the cabin air filter, replaced the underdash panel (correctly, with two hooks engaged). After all the success, discovered that the flapper door is not functioning completely correctly. With fan on high, normal heat settings, activating "recirculating" button moves the flapper to closed. But deactivating the "recirculating" button does not cause the door to open. If nudged by hand from the cowl side, the door seems to overcome a catch, then open. I have sprayed the door and hinge with silicone spray and am hoping patience will be rewarded. Here in Iowa, not planning this to be a winter driver needing defrost/defog, but fresh air in the summer might be nice. Once I close the cowl, I won't know what is happening. I expect that searching fan replacement might give me some idea how to reach this area from inside the car. After replacing the cabin air filter, I'm not really looking for another opportunity to stretch an old body while standing on my head.

Thanks again, guys.