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Yesterday I went through our pile of the latest batch of single toggles. Roughly 20% of them were defective. From now on, every switch will be tested before installation. Sorry for the inconvenience.
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Bob, does this mean you'll send me a new one for free???? Just asking...
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Two ways to do that: cover the lower 1/3rd of the rad with sheet aluminum / don't drive on less than 55 degree days.
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I'm looking into doing just that, but yesterday I also found that I was using the wrong diameter thermostat, which might allow too much bypass action. I'm going to swap out the thermostat again today and see what the effect is. If that's not enough, I'm going with a Lexan cover.