RE: Blower motor continued..

["Buchholz, Steven" <Steven.Buchholz@kla-tencor.com>]

> When I reassembled my heater box, I followed a technique I believe
> nobody's
> mention before.  Simply stand the heater box on end with the flap axles
> vertical.  This minimizes gravity's effect pulling down on the axles while
> you frantically try to align them.  As I recall, the heater box has some
> extra plastic shoulders molded in to help keep the axles in place.  As I
> lowered the 2 halves together, I used an ice pick to guide the ends thru.
> No drilling and I think the whole thing went together rather pain free.
> 
... I guess I didn't state it explicitly, but that is what I was doing.  It
is pretty hard to guide 2 big pieces of plastic with a bunch of loose flaps
without setting one of them down!

I must say that you are more skilled than I was ... that was what I was
doing, but I couldn't keep ALL the flaps in their guides long enough to get
the halves close enough together to even reach them with a straightened
dental pick (what I was using).  What I found was that by setting the
coupled blend doors in a particular position they would tend to remain in
place, which greatly reduced the degrees of freedom!

Before doing the job I thought that the Audi tool was used to calibrate the
positions, but now I know it was just to hold them in place.  If I ever saw
one it should be possible to use it as a template and cut something from
cardboard or some such material.  Once that was done it should be pretty
easy to put the template on a website in 1:1 scale, making it unnecessary to
drill or pick at all!

Steve Buchholz
San Jose, CA (USA)