Hi. We have just purchased a 2004 Mini Cooper. The car is fantastic but has one quite annoying problem. Whenever the aircon is switched on, the drivers footwell gets quite wet. I've added a couple of pictures below to show where the water is coming from. I'm guessing there shouldn't be a hole in the casing? Any ideas whether it is possible to replace this part?

Thanks all!

There is small drain pipe for the condensation formed on the cold evaporator in the middle of the black plastic heater/aircon casing which then drains out under the car. You therefore need to block up the crack/hole shown in your photo that has been broken/formed in the side of the plastic casing, so that it once again only drains through the correct central drainage outlet.
I guess the hole was caused by an accidental impact perhaps from someones shoe/toecap!
To replace the heater casing even using secondhand parts is a big job as the whole dashboard/ heater assembly would have to come out to remove it......far easier to block up the hole by gluing/bonding on a plastic repair plate/ waterproof amalgamating tape or similar.

Diagram of heater casing:
RealOEM.com BMW R50 Cooper Actuator, heater and air condit. (http://www.realoem.com/bmw/showparts.do?model=RC32&mospid=48010&btnr=64_1148&hg=64&fg=45)

No.7 here is the condensation outlet hose which sits underneath the heater housing on the centre tunnel:
RealOEM.com BMW R50 Cooper Housing parts, heater and air condit. (http://www.realoem.com/bmw/showparts.do?model=RC32&mospid=48010&btnr=64_1145&hg=64&fg=35)

Brilliant, thanks for your help. I will get a piece of thin plastic and I've got some epoxy resin in the garage somewhere which should do the job nicely!

Any idea how I can find the A/C drain on a R56?