once i was ready to take a break and clean up all the crap i noticed the dirt made a smiley face haha..yeah its the little things in life =)
 http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2418.jpg ][/img]
I started by removing the 3 gold screws that hold the motor to the metal bracket, once these 3 screws are removed the motor simple pulls back and slightly rotates to come off the bracket. behind the motor/bracket, there is an actuator arm that moves the bar controlling the position of the vent doors, just keep the orientation of the motor, actuator arm and bracket for vent doors in mind. this will make re assembly much smoother for you.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2422.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2424.jpg ][/img]
now remove the 3 black screws that hold the bracket to the blower housing and remove the bracket itself.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2425.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2426.jpg ][/img] never mind, sorry. THIS is where my camera died, so from here on out i will still show the process but somethings wont look 100% the same, because by now i have already recovered my vent doors with new foam, ect, ect. because i was too impatient to wait for my battery to charge.
but again, i tried to document every step. now that you have removed the motor and the bracket for the motor its time to remove the doors. they attach to a bar via two tiny phillips/flat head screws. (when removing or installing remember to support the blower motor housing behind the screw locations, and apply firm pressure while removing, otherwise it is VERY easy to strip these tiny screws, and if that happens. well your on your own because i avoided it lol.. now in order to get to the screw for each door, the bar controlling the doors must be rotated to a certain position. lets start with the larger of the two doors, to get to the screws holding the door to the actuator bar you will need to make sure that the actuator bar is in a certain position, seen here:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2495.jpg ][/img]
having the bar in this position will represent the motor being set to recirculate, opposed to fresh air. this will allow you to get to the two small screws at the top of the door, seen here:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2496.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2497.jpg ][/img] once screws are out and safely set to the side you can push up on dor through hole andromve door from blower motor housing at an angle. next rotate the actuator bar in the opposite direction so we can remove the smaller of the two doors. ok now the little door first, to do this make sure the control par looks like this:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2498.jpg ][/img]
that will allow you to get to the mounting screws from the bottom of the lid, you might need a long shaft screw driver for this part.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2509.jpg ][/img]
ok here is a quick set of pics showing how to rotate this piece for removal and re-installing:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2508.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2506.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2505.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2504.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2502.jpg ][/img] once both doors are removed, the two actuator bars are now free to be removed, pull up and out with even pressure on both bars at once.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2487.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2486.jpg ][/img]
now that all that has been removed you are left with one part remaining, its a thin piece of metal that sperate the top housing from the fan blade in the lower section of fan motor housing. before you remove the 3 screws on the underside, holding this plate to the upper housing, take a sharpie and draw on this piece of metal, tracing the the opening on the top side of the metal (inside the upper housing), this is to get a template for the piece of plexi you will be installing. the plexi will make the top layer of the sandwich, and this steel plate will be the bottom layer. when everything is said and done the new filter you make will slide in and out BETWEEN the two layers (plexi you add and this thin piece of steel)
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2511.jpg ][/img]
here you see the 3 screws holding in the plate, and the plexi already added to the other side. that other side is the side you want to trace onto with the sharpie. once i traced the size of the opening on the upper side of the steel separator, i transferred that shape to a piece of paper, this paper is what i used to get the shape i needed for the plexi. I used a steel ruler for a flat edge and a sharp razor blade to score the plexi like 15-20 times, this will leave a deep enough groove in the plexi that it seperates from the rest of the sheet easily. be patient with this step. dont need to cut yourself, or crack the plexi. once the shape is cut from the plexi you can set it into the opening and trim it were needed. (i used a dremel sanding wheel to take off as little material as possible, that way i didnt over do it. again patience is needed here. once i removed enough material in the right places the new plexi sat nice and flush inside the opening. you want there to be a nice 1/8" gap between the bottom of the plexi you just added, and the face of the steel to be bolted back on. this gap between the two pieces is where the filter will slide in and out of. [img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2440.jpg?t=1338008699 ][/img]
i used some 2 ton epoxy from devcon to fasten the plexi into place. [img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2536.jpg?t=1338009093 ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2535.jpg?t=1338009098 ][/img] notice the nice gap bewteen face of plexi and mating surface of steel seperator? i test fit this piece of plexi, and reshaped it almost 9 times before i was happy with fitment and epoxied into place, again, be patient!
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2528.jpg ][/img] i used MS paint to highlight where i applied expoy to the housing before i set plexi into place.
i let the epxoy fully set before going onto the next step:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2527.jpg ]">
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