Got some more done this week! The good news is JB Weld (orginal) is compatible with ABS plastic and worked well. The bad new is I lost 1 of the broken pieces. Iím going to try it anyway with the piece missing. Should still work for manual operation of the blend door.
I tested the jb weld on the back of the door just to see how well it worked. I did this in two spots, one spot I sanded and the other I didnít. The weld works much better in the sanded spot. The way the door is made makes sanding a big job so I used a dermal tool with small disks. With the plastic ruffed up I applied the JB weld in layers building up the axle. Had to allow 3 hour drying times between coats. Here is a picture of the door in a jig I made for the fit.
The manual door handle! (below)
Its made up of a piece of 3/8ís tubing and a 1/4" keyway JB welded into the tube. The washer that fits to the end of the key way is from the back of a GM alternator designed for a square bolt , you will half the cut some of it off for the square fit of the keyway. I then JB welded it in place, the idea here is to make the washer flat for a piece of Velcro material to stick to. Another piece of Velcro will be placed into the axle shaft to make the connection of the two pieces.
Thats where Iím at now, post more when I know more.