For those who have swamp coolers that are controlled by Dial’s electronic thermostats… You may have already experienced that the door has given up the ghost and the hinge tabs have broken off. I have found it is probably due to it being left open and somebody running into it and hyperextending it in all but the correct way. Well, I’m sick of my thermostat door falling off and so I replaced it.
I took a “soft box” shape and dimension it to the exterior dimensions of the original door. Then using the original door, I measured each cutout I needed to make it functional. As you can see it’s just two basic shapes with a lot of subtraction.
The only lessons learnt from this is the hinges rely on some give to allow you to attach the door to the controller and depending on which way you print, that small extension may break… It is the strongest printed upright as shown. To improve it aesthetically, I would flatten the face to make it contour with the controller better for the next iteration.