I was experiencing an issue... where, with the defroster at max, I would get intermittent bursts of air flow to my feet.

The dealer said that there is basically a piece of foam that blocks the vent up to defrost, and under full fan speed, it can indeed get pushed down... So not a huge problem.

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05 KC SE Smoke
01 Suzuki 600 GSF
88 Fiero 2M4

Hmmmm, that's interesting. I figured out that my flapping sound is when I go from defrost to body flow but not from bodyflow to defrost. The doors operate by applying a ground or power to opposite sides of the motor thus reversing directions thus making me think I may have a bad connection (Probably ground) causing the door to cycle.

No flapping sound for me, just an intermittent breeze of air at my feet while the defroster is cranked all the way up.

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05 KC SE Smoke
01 Suzuki 600 GSF
88 Fiero 2M4

Maybe when I'm in the dash I'll be able to shoot a pic of that? I'll keep an eye out.