A process and apparatus for insertion of a stuffer plug (18) within a hollow section of a automotive weatherseal extrudate (10) is provided which operates by insertion of a needlelike section (20) of a dispenser unit through a wall of the extrudate into the hollow section. A stuffer plug precursor is then injected or inserted into the hollow section and the needle-like section of the dispenser is removed. The stuffer plug precursor (22) then forms a stuffer plug (18) within the hollow section. Preferably, the stuffer plug is a two part polyurethane which reacts chemically to form a polyurethane foam stuffer plug (18) within the hollow section. An easier method for establishing a stuffer plug (18) within an extrudate (10) is provided.