Time to turn my cardboard prototype into a permanent bracket for the heater valve.
Since this bracket will sit freely, I decided to use 0.05in thick aluminum to give it some strength.
Just like the standard bracket that would usually hold the bowden cable, I designed the bracket to mount into the heater valve unit. So I added the size of the screw mount portion of the original bracket to my cardboard bracket part.
![Outlining the bracket to cut](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_222746690_iOS-1024x768.jpg)
![rough outline of the bracket and adding some indicators for the 90 degree bend](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_222901032_iOS-1024x768.jpg)
With the outline made, I got out the aviation snips and started cutting out the bracket.
![Bottom part of the bracket cut](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_223639489_iOS-1024x768.jpg)
![Bracket cut and 90 degree bend location marked](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_224139974_iOS-1024x768.jpg)
Next step, releasing some tension. To make the bend, I mounted the bracket along the bend line in my bench vise. And then gave it some gentle (read strong) taps with the rubber mallet to form the bend.
![Bracket mounted in my bench vise with some wood to bend it along](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_224552651_iOS-1024x768.jpg)
![Whacking the bracket to form the 90 degree bend (very satisfying)](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_224643910_iOS-1024x768.jpg)
And here it is, a nicely formed 90 degree bend.
![Bracket with the bend completed](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_224759569_iOS-1024x768.jpg)
![New bracket along with the original bracket to check the bend is aligned](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_224817962_iOS-1024x768.jpg)
Next I deburred all the edges and rounded out the corners.
![Deburred and corners rounded](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_230139036_iOS-1024x768.jpg)
And then I match-drilled the holes to mount the bracket to the heater valve using the original bracket.
![Match-drilling the bracket holes using the original bracket as a template](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_230445097_iOS-1024x768.jpg)
![Bracket mounted on the heater valve](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_232019459_iOS-1024x768.jpg)
Finally, time to mount the servo to the new bracket. Quick test fitting with a clamp to get the travel distance right.
![Final test fitting of the servo](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_232959920_iOS-1024x768.jpg)
And then I drilled and mounted it to the bracket.
![Servo mounted.](https://slingtsi.rueker.com/wp-content/uploads/2021/03/20210316_235146678_iOS-1024x768.jpg)
And here it is in action: