Thanks - I've read a good bit on your method and the Cool Harness too but I think it just might be easier to shorten the pin if filing it down .015 throws it on at 92C. Makes sense, filing down a little more would kick it on at 90C.

If I remember right, bumping the bimetallic strip out about a 1mm with your mod gives full tilt. How much did you do or adjust it to get it to kick on at 90C?

My notes show full pin deflection to be about 0.070 or 1mm full-tilt deflection to be .039.

Tips, tricks, cheats, suggestions anyone?

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94 E320 and 84 380 SE now - past Mercs include 68 280 SEL, 74 240D, 77 240D, 80 300D, 84 190E