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Any reason you didn't try the hack whereby you remove (drill / grind etc) the top of the heater box to expose the top plug of the flap axis? You can then just reach into the front section of the heater box and remove the flap. Relatively speaking, not much needs to be removed, and you just re-install the flap and cover the plug with tape or a bit of tin metal fastened down etc... works a treat... !!
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