The inside of the heater box was freaking diguisting. It was very difficult to stop myself from scraping the lot out with my tongue.
![Image](http://i.imgur.com/24lSEs3.jpg)
I decided I had more degreaser than saliva anyway.
![Image](http://i.imgur.com/BG8wsxn.jpg)
I soaked the old foam off with thinners and used a wire wheel on the drill whilst submerged to get rid of the adhesive. I replaced the adhesive with strip i found at the hardware store.
![Image](http://i.imgur.com/inVdJtR.jpg)
Tongue didn't quite reach down into all the crevices.
![Image](http://i.imgur.com/YpEJfi9.jpg)
This was broken, luckily one was easily salvaged from the spare sigma.
![Image](http://i.imgur.com/qEXje5v.jpg)
More foaming. Core look innocent there but it caused me two days of suffering.
![Image](http://i.imgur.com/WSIRdvt.jpg)
Looks simple right?
![Image](http://i.imgur.com/TAtbHkT.jpg)
Looks really simple.
![Image](http://i.imgur.com/BLm9pmX.jpg)
This setup actually worked. Pity it worked in reverse, turning the valve on with the cold setting.
![Image](http://i.imgur.com/e38HeGY.jpg)
Revision 2. This literally took hours to get working properly. Cable outer is bicycle gear cable. Inner is mig wire. Lever ratio was a total guess but was perfect. Outer bracket is tigged to core retainer bracket.
![Image](http://i.imgur.com/cD41hxq.jpg)
I couldn't recycle the old pipework or bend new copper on a tight enough radius so I just used plumbing crap from the hardware store. It a larger diamter than the original pipe but that's what I could get. Soldering was achieved with a pencil torch and took forever. I sanded the surface off the valve, sleeved it into the pipework and filled the shit out of it with solder.
![Image](http://i.imgur.com/BTp4zqG.jpg)
I ended up gridning some metal off the valve to make it fit nicely.
![Image](http://i.imgur.com/Rgwqszy.jpg)
Fan motor was full of crap due to the shitty ventilation design. I ended up using parts from a spare unit i got from the wreckers.
![Image](http://i.imgur.com/ZxOgwxB.jpg)
I just used sandpaper on a flat block to clean up the commutator. I lubed all the bearings with heavy duty bike chain lubricant.
![Image](http://i.imgur.com/QCgLgrd.jpg)
Fan had more flaps that had to be foamed
![Image](http://i.imgur.com/YTqMDmc.jpg)
I stuck the windings of the fan resistor back together with some muffler putty.
![Image](http://i.imgur.com/zQkjjyf.jpg)
Lots of thick foam is important here as its a crap fit to the aircon from factory. I also found this with some of the ducting which i taped.
![Image](http://i.imgur.com/2ki9u48.jpg)
Finally seeing the light at the end of the tunnel.
![Image](http://i.imgur.com/vJqLNgt.jpg)