I have had the same problem and used almost the same solution.
It is possible to make the hole in the heater casing into a slot in order to
remove the heater flap with a small saw.
I then used a small piece of steel sheet of the same gauge as the heater
box material to close off the slot when the flap was reinstalled. One end
of the new material was made large enough to be secured to the heater
casing with two small pan head screws, I used 2mm but I guess 2-56
would be about the same size.
Used Loctite on the threads and there is no problem with the short projection
of screw into the heater flap area as the shaft holding flap has a shoulder on
it which will stop it sliding into the screws.
Hope this makes sense but the mod has worked well for me.
John Dowson
At 12:21 PM 5/15/99 -0400, jaltman@altlaw.com wrote:
>
>Mine broke a couple years ago. Its pressed on and appears to be impossible
>to fix without replacing the whole heater box. What I did was cut a small
>slot where the shaft protrudes. Bought an otherwise destroyed box with a
>good door. Cut that door out. Fit the replacement door in through the slot
>and put a clip (like the ones they use to screw the cardboard pieces
>together but with the screw hole clipped out). It fell loose a couple times
>till I got it tensioned right, but has been stable for a year and a half.
>
>
>
>Jim Altman jaltman@altlaw.com Illigitimi non Carborundum
>http://www.altlaw.com/metro/jaltman.html 69-TR6#CC28754L W4UCK
>
>
>-----Original Message-----
>From: owner-triumphs@autox.team.net
>[mailto:owner-triumphs@autox.team.net]On Behalf Of Peter Zaborski
>Sent: Saturday, May 15, 1999 8:58 AM
>To: 'TR6 List'
>Subject: tr4-6 heater question
>
>
>
>Listers,
>
>It appears the TR4 through TR6 used the same (or a very similar) heater. On
>this heater there is a small aluminum (or perhaps pot metal) "lever" which
>is attached to one end of the shaft on which the air control "flap door"
>pivots. The heater control cable attaches to this lever via a trunnion and
>screw. Does anyone know how the lever is attached to the shaft? My lever
>broke last night and I would like to know how to safely remove one prior to
>heading out to the local British junk yard. [ Safely meaning without
>damaging the lever :-) ]
>
>Thanks in advance.
>
>Peter Zaborski CF58310UO
>
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