Thanks for this awesome post. I followed it and was successful.
The hardest part of the job was getting the 3 semi rusted screws out of the fan! Once the fan was down, we reached up into the hole and positioned the broken recirc door into the recurculating position. I held it there as my friend slid a small wood wedge that he had made into the plastic "grill" thing behind the glove box. It fit perfect and the door was solid shut. A bit of hot glue on the wood wedge and plastic grill and it was done.
The AC is blowing like a hurricane and super cold!
Thanks again from BC Canada