So, onto the next attempt. This time I used a metal arm secured to the shaft with a centre hole and self tapping screw and bent around the lower part of the shaft where its flat. Then 3 screws onto the side of the flap. So far so good, but I need to test it more. If it tests okay for a few days I’ll reattach the missing piece.

Click image to enlarge

Well done, I drove around for around two years with a pair of plastic electrical conduit tubes cut to length holding the flap permanently closed in the recirculate position before I tackled this dog of a job.. must admit she has held up fine to date… Still have the tubes in the glovebox, just in case..

Thanks. Yeah it’s an absolute dog of a thing to fix. It’s not pretty but it works for now!