I completely removed the changeover flaps last year before I discovered that I could have just epoxied them in place to open the short runners (low RPM mode). Now that the IM is going to come off again, I was hoping to fix this, but now I can’t find my old flaps.
Anyone willing to give me theirs?
(And I’m still hoping to hold out until there is a JHM IM upgrade out there)
Hopefully you can find yours, or someone has a set they can send you, but I think the flaps aren’t a part you can buy by themselves. Which means if anyone has had broken flaps, they’re probably either glued-in-place like you want to do, or they got returned/sold when the manifold got completely replaced.
I, too, hope JHM can come up with some kind of solution for us, but who knows if they can, or when that would happen
There have been a few users on here that have posted about broken intake manifolds. try pming them and see if they still have their old intakes. I think if they still have there old itnakes they would be happy to send you the old flaps
I havent had my intake apart yet, but just from looking at pics, it seems one could take a long steel round cylinder rod, have a shop machine a flat groove along its length, and then slide and epoxy or stake the plastic flaps in place if im not mistaken? Then you can just press thread and bolt a cam on the end of it to receive the actuator linkage and bobs your uncle.
As i understand, the flaps themselves are fine, its the fact that its all just 1 big injection moulded piece, and they break at their fulcrums?
Everything is plastic.Even the mounting tabs. Since there is just one arm they are all linked together. Its a mess. Not only that but they are an interference fit piece. So there isnt anything to even screw a new possible arm to
exactly my point. make a new rail out of metal, press the arm cam on the end, press and stake the plastic flaps onto the slotted metal rod. Should be no problem. If someone wants to send a broken manifold Id be glad to make some prototypes 
I wish I had my broken bits. Someone please do that. I’d be
from some brief reading, the 4.2 v8 have this issue as well dont they? in the s4?
IF so, it appears to be the exact same mechanism sans 2 cyclinders. if this is the case, trying it on a 4.2 manifold woudl be good practice as there are way more 4.2 than 5.2 out there. Again, if someone wants a trial run, id be glad to give it a shot.