Defiant Encore 2190 primary air cable sticking

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Jchap44

Member
Nov 10, 2017
11
Minnesota
Hey all. I rebuilt almost all of my encore 2190. Worked great last year! The primary air cable snapped and I could not get the door assembly off the back as I almost rounded the screws off. Tried everything. So I essentially spliced the wire with new wire and all looks good, except for when I install the right side the cable gets stuck. It almost feels as if the side gets too tight. Guessing I need to regasket it. Has anyone ever had to shave off the screws on the primary air door assembly to remove it? Just curious. Thanks much.
 
As I recall those are P3 pan head 1/4-20 screws? Either vice grips or take a dremel and slot them so you can use a big slotted screw driver, when you replace it using regular hex head bolts.
The dremel fix was my next move. Might end up shearing the screws but I will be able to deal with that it so. My other issue is the side panel and causing the thermostat and wire to get hung up. I believe i have to get new gasketing on because it feels like theres not enough room and with the new gasket it will give enough room to work the primary air lever. If that even makes sense.
 
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