Here is a pic of the arm. Not the white arm but the black one behind it. I circled it with a yellow line. I will pull the existing and see if I can make one. Now I wish I had a mill.
http://i273.photobucket.com/albums/j...oe/flaparm.jpg
Printable View
Here is a pic of the arm. Not the white arm but the black one behind it. I circled it with a yellow line. I will pull the existing and see if I can make one. Now I wish I had a mill.
http://i273.photobucket.com/albums/j...oe/flaparm.jpg
Cleaned the shaft where the plastic flap broke off. Then spread some JB Weld along the broken edge of the flap, tried to make it a thin line just on the edge and the thickness of the plastic flap. Stayed away from the edge about 1/4" (see photo). Then I pushed the other flap closed in the other vent, this makes it easier to position the flap into place and gives it support on three of the four edges with the forth edge being the broken edge. Carefully place the broken flap into place making sure not to get glue anywhere except the break. Once the flap was in place I then smeared JBWeld along the broken seam. with a popsicle stick. Making sure not to get it too thick so it doesn't get on any other parts. That was about 2 hours ago, just went out to test it and it worked. Once it sets up over night I will apply JBWeld to the other side. I also spread JBWeld on the other flap, It has a couple of hair line cracks on it too. This is a tight area and my head was against the windshield and had to fight to get one eye into position to see down the hole :) Isn't the prettiest job with glue I have seen but if it works who cares ;)
http://i273.photobucket.com/albums/j.../flapglued.jpg
Great, man!
Pics will go onto shogun's site.
If you have anything to add or more pics, just add it here, Hairywithit will make the final write up in concentrated form with pics.
Will help a lot of people with same problem.
Here is my first attempt at the actuator arm. Need to find some 3/8" brass rod, to make the last part
http://i273.photobucket.com/albums/j...rstattempt.jpg
Well I finally got it all back together today. Here is a pic of the actuator arm I created. I built it out of three pieces of aluminum and welded them together with alumiweld. Amazing stuff... Anyway arm worked and you can do this repair without removing the IHKA. I could make this arm for other members but it takes about 3 hours of machining and welding, so it won't be cheap ;). Also found out why the flap broke. The stepper motor was pulling to far so installed a shim between the stepper motor arm and the stop. I also reinforced the mounting bracket with JB Weld, filled in all the holes and then wrapped it with parafilm until it set up.
http://i273.photobucket.com/albums/j...ctuatorarm.jpg
very nice!
Post that also on Bimmerboard E32 forum with the pics and a short writeup. Maybe you also mention the price for these parts if someone is interested to buy.
Use the test forum there first to see if the pics work.
Thanks a lkot, good stuff!
I'm satisfied my explaination for the green residue under the car is that it is windshield washer fluid entering the air box and draining out with the A/C Condensation.
As far as the other...not yet.. I have to take the dash apart soon to replace a CD changer cable and change some bulbs in the cluster. At that Time I'll inspect the stepper motors and see if I notice any arms broken.
The plastic mount for the bottom belden cable has broken off the air box.I'll JB Weld that on then too... This isn't a huge problem for me yet becasue despite daily blather about global warming the temps up here are unseasonably low and the present functioning is adequate but when Hot Summer temps arrive I'm sure I'll have motivation to try changing the Climate Controls, The IHKR Unit and the heater/Water Valves..
I have two left and I am going to keep one for a pattern :)