self-adhesive gasket
Does there exist a self-adhesive gasket that doesn’t migrate over time? I lined a return filter grille with gasket material that lasted several years, but over time the pressures in the area seemed to pull the gasket into the return plenum.
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There are gun-applied foam-like gasket materials, but I’m not aware of any that are available in less than industrial quantities. You might try some of the silicone D profile weather stripping instead, which is a relatively soft, but still solid (not foam) material that shouldn’t migrate.
Bill
I get the sense that it's the adhesive at fault, not the foam gasket material itself.
You can purchase some high temperature sealant at your local plumbing supply and use that to secure the gasket. You may be able to find a similar product at an auto part store as well for sealing high temperature gaskets.
Tom, why high temperature?
They are designed to withstand a lot more than just silicone or other types of adhesives so they should outlast and outperform. Your return duct will still have some heat associated with it so just an extra precaution. If it is a paper gasket it will compensate for any moisture it may absorb.
You might try butyl rope caulk, I have never used it other than metal roofing so you should check the SDS to see if it’s suitable indoors, but its pretty good stuff.
They make an expanding gasket material as well, again for metal roofs, that has adhesive on one side as well that might work great depending on your application.
Google:
Emseal Multi use sealant tape.