Defroster Divertor box repair

[k5hart]

During my never ending heater core replacement project I realized that the flap in my divertor box was cracked. This is a common problem with our trucks and will cause the air to not redirect out of the defrosters. I wondered why my defroster sucked! Anyway, a few people suggested that epoxying the door was a possible solution but some didn't think the repair would last. That got me thinking about what would last. Something that would add support on top of re-attaching things together. Here's my fix.

I took a piece of flat steel bar I had around and cut it to size. I put a small angle on one long side so it would slip under the rubber piece that surrounds the door. You will have to take a razor blade and cut one nub out of the rubber in the middle of the flap so the metal will slip under. I painted the top so it was clean and left the glued side raw steel.



Then I used a 3M adhesive made for attaching emblems. It sets up somewhat rubber like but very solid and is strong as heck. It takes a day or so to set. As you can tell I used a lot, coated the bottom and put a bead around the steel.



I haven't put this in use yet but I've done two different boxes and tested (played) with it a lot and so far no problems. Just thought I would share my idea and see what ya'll thought.