If you are inclined to try some form of glue/epoxy, then you might want to look at some of the kits that are available at parts stores. They have kits for repairing gas tanks and for plastic tanks etc. Usually not much more than a bit of epoxy, some small pieces of fibreglass cloth and some sandpaper for a big price but there may be some merit to the idea. Don't know for sure if the epoxy is different for different purposes etc.
I know, that we had good luck with one that we used to repair a gas tank on an old Jeep.
Randy On 08/02/2012 4:20 PM, Scott Ritchey wrote:
For some years, the floor heat in my 1982 300SD hasn't worked. Limited investigation showed that the floor heat flaps moved freely (as if no connection to any linkages) so the flaps simply "blew shut" when the blower ran. We had a spell of warm weather (50s F) so I decided to attack the problem this week. Now the back seat is full of floor mats, center console, under dash panels, etc. Here's what I discovered so far. These flaps (one left and one right) have a splined shaft at the top and that's what broke. So the flaps need to be replaced. The right flap cost is reasonable (like $40) but the left is outta sight (like $200). Here's an operating schematic: http://kittrellcommunitywatch.dyndns.org/HVAC/floor_heat_schematic Here's the general layout: http://kittrellcommunitywatch.dyndns.org/HVAC/heater_case Here's what the parts actually look like: http://kittrellcommunitywatch.dyndns.org/HVAC/parts Note the splines on top end of the flap shaft. The black parts go on the left and the white parts on the right. The white lever-gear snaps apart into the lever/gear (top) and a keeper that snaps in from below to lock it in place On the left flap, a lever arm slides onto the splines and "snaps into the heater case: http://kittrellcommunitywatch.dyndns.org/HVAC/left_flap_lever On the right side, a gear slides onto the splines and that gear mates with another gear with a lever similar to the left side. http://kittrellcommunitywatch.dyndns.org/HVAC/right_flap_gears The metal action bar that engages the ends of both of these levers such that when the bar moves left the left both flaps open. The action bar has a 90 degree arm pointing down and the vacuum element pulls the bar left under vacuum and moves it right via the element's return spring. So much for sharing what I've learned so far. Now here's my current problem. As a minimum, I think I must separate the upper and lower heater case to install the new flaps. I don't know if I can spread the lower case (from the upper case) sufficiently with the heater box still in the car and I don't want to discharge the R12 AC system or pull the dash and steering wheel. If I have to pull the heater box from the car to fix this, I'll just try to put it all back together and learn to live with the problem (i.e. not use the car in winter). So my question is. Does anyone know if it's possible to replace these flaps with the heater case still in the car??? Thanks. Scott in NC _______________________________________
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