What is proper method to remove Beverage Air ER-48 door gasket track to gain access to change door handle?
It requires shutting down the cooler, Making a flat area to place the door on that is level and square. Removing the door and laying it fully supported on the flat surface. Failing to do this will result in a warped door as the inner door and outer form the strength when assembled. You will probably want to have a new gasket on hand as well. I'd say you might want to just replace the door, But the ER series is no longer made or supported. Often separating the panels causes damage that makes it very difficult to reassemble it square.
Did the handle come loose or break? As I recall the ER's had a very sturdy handle. I have in the past used sheet metal plug cutters to gain access to the screws for tightening and than filled the hole with foam and a metal snap cap over it. Like a 1/2 or 3/4 electrical knock out plug. You can take a piece of EMT conduit and sharpen the edge to cut out the insulation.
Handle is missing, but screws are still in place.
I like your idea of cutting holes in the interior panel to gain access to
the screws and just foam filling access hole in insulation and installing
I had wondered about doing that but thought that the gasket track might
snap out okay with slight heat from blow dryer.
I can't find an illustration of the gasket track to understand just how it
holds the inner metal panel inside the outer metal door housing. Seeing
that might help know how to remove the track without cracking it. I
considered using a large 6" wide putty knife to apply pressure over a wide
area to fold it inward slightly to release it from the door frame but that
might not be how it would best come apart. Don't want the customer to be
without for very long.
There is one other option. Obtain a handle with front screws from Kason like the P48 series and use nutserts in the outer door.
only you know what your customer would be happy with. I do not recommend splitting the door, as the insulation is put in just before pressing it together in a jig and acts like a glue. Not like what we had back in the fifties and sixties where they were assembled with screws.
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