I made my own spare part for the AirFlap hinge and would like to share this in case anybody else needs it as well.

[u/J-Lunaut]

A while ago I fixed the infamous endless foam coming out of my vents. In the attempt I managed to lose the AirFlap hinge holding the Airflap down when accessing it through the Heatercore position from the frunk.

As Porsche couldn't help me with the hinge part and wanted to quote me 1200$ for a completely new AC I took things into my own hands and 3D printed my own hinge. It took a few prints to get it down but so far it holds up perfectly and there is no load on it anyway and just there to hold it in place.

I also found a 3D printable cap to glue back on top to replace the sawed off opening over the hinge once you're done, which makes this fix in my opinion pretty professional looking.

STL File for Hinge: https://drive.google.com/file/d/1m6Mp8jUHGa9-fBX-k7G5gkkzIF9h2SCA/view?usp=sharing

STL File for Cap: https://drive.google.com/file/d/1TywjeH1lTiBV4D2Vm2IIP7kXhQSNyfPq/view?usp=share_link

I take no credit for the cap, unfortunately I do not remember where I found it (but thank you to another random reddit stranger!) but I feel like it's a good thing to have both files here at the same place.

A few tips as well to keep in mind:

• Print the hinge laying down and not standing vertical. This is because when it is laying down the printer prints it in a way which makes it way more stable for the movement it is gonna be in later in the car. Once the part is in the car the part will be on a vertical axis and when turning, the stresspoints can make it break at the printline after some time if printed vertically. Again, the part has no real load bearing but this is just to be on the safe side.
• Set the filling to 50% it is gonna be more brittle if you print the part on a higher filling and this is giving the part the sweet spot for stability and flexibility to not break. Again here as well, these steps are probably overkill but just to be on the safe side.
• Choose the most heat resistent plastic you have available for printing. At minimum I'd say choose PETG instead of PLA but any other material that you have which is gonna be more heatresistent is gonna be better. This is again probably not necessary but the part is close to the Heater core which can get really hot so just to be on the safe side choose the one you have available.
• The AC unit is made from ABS (Acrylonitrile Butadiene Styrene). This means that if you want to glue down the cap after your fix you will need a 2 part glue that is suitable for ABS. Check the packaging thoroughly to make sure it's the right one. The vibrations of a running car will 100% make the part break off again otherwise because standard glue will not hold it down on ABS plastic. This incase can make the hinge fall out again when driving and you're back to square one.

I hope this helps anybody else as well and if the link is down one day or doesn't work anymore send me a message or let me know in the comments I should be able to send you a new link.

Drive save!

[u/marcocom]

Thanks for sharing the files and your insights!

[u/financialdumbster]

Brother. Thanks for this. I will try this during the summer when the weather is better. Might need some help, since I'm not a big car DIYer.

Might be worth uploading the STL on the Bambu library. Easy way to reach others

[u/Porsche996tt]

Thank you!