This website was among the more helpful sites as it provides Jeep's Repair kit instruction. Thanks for a well thought out site, and permission to borrow content.
This site does a good job of where and how to cut, so I will not re-invent the wheel. I'll show you my solution to the kit from Jeep.
Total Cost of Project:
$1.76 Mending plate ($0.88 x 2)
$3.36 Hinges ($1.18 x 2)
Required Materials / Tools:
4 - 1/8" rivets
1 - Rivet gun
hacksaw or rotary tool (the hacksaw requires more patience than I possess)
Step 1: Problem...
I decided on a standard 3 inch door hinge as my new pivot point. This stamped steel piece should be more than sufficient to withstand the calibration forces. The door is a reinforcing plate typically used on decks and truss frame construction. These both will be very easy to find at your local home center. The truss plate is found in the pressure treated section. You will need 2 of each to complete both blend door repairs.
Step 2: Solution...
Step 3: Fit the OEM Connector
Using the OEM connector (the white piece) test the fit. Mark a line where material is to be removed to allow the key to fit. Remove material with a rotory tool or hack saw. The fit between the OEM connector and the hinge has to be incredably tight. The amount of torque that is aplied to this piece in insane. Be patient, b/c you will probably have to install, test, remove and tighten several times before you get it right.
Step 4: Add Door...
Step 5: Trim to Fit...
Repeat steps 2-5 for the other door.
Step 6: Connect Doors...
Step 7: Install and Test...
Push the new door onto the connector and slide the connector pin all the way into the installed door.
Install the second door, sliding the connector pin into the far side of the second door. Align and snap in the near connector.
Reinstall the near actuator and test. When you put the ignition to run and turn on the climate control system it will run though the calibration test that broke the OEM equipment to begin with. Watch the doors move, and pay attention to the amount of torque applied to the doors - the plastic ones didn't stand a chance! Be prepared to remove and tighten the connector / hinge mating. Once you are satisfied the connection is secure, duck tape the doors to cover the holes. Replace the cut piece of plastic and tape, and you're finished. Now...what to do with all that money you saved...hmm....