512TR AC Blower Problem - Broken Flap or Valve

I have a 1994 512TR with a broken flap in the AC blower assembly. My car initially suffered "only" from what appears to be the notorious TR power transistor problem discussed recently in another thread. I have been living with the fault as the blower fan could operated at full speed, which in summer in Texas was its normal setting. However, just recently when I started the car I heard a noise in the blower which sounded as though something was stuck and rattling around in the blower fan. I decided it was now time to fix the transistor and find the blower noise problem. The dash had to be removed to get at the blower section and the mechanic discovered that the noise was caused by the flap/valve on the intake side had broken and parts of it were ingested into the blower fan. The flap or valve I am referring to can be found within the red circle on the attached diagram. (I can't remember if it was the right or left side) Unfortunately, this $2.00 plastic flap or valve seems to only come with the entire blower assembly which is a multi thousand dollar part.

Our options at this point are as follows:

1. Reinstall without the flap or valve. I don’t know what the side effects would be to having this always open. I am not really certain of the purpose of this flap or valve

2. Have the part fabricated out of aluminum at significant expense

3. Find an alternative or used part out of some Ferrari, Fiat or other manufacturer’s product. Anyone’s thoughts on the availability of such an item would be greatly appreciated.

Any other thoughts or options would be extremely helpful.

Thank you very much.

Lloyd
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