Door handle salvage and repair

[dmaddox]

A new friend stopped by to pick up some parts and also noticed my driver door handle was loose. I noticed this as well, and thought "I'll get to it". After carefully removing the door card, I thought (according to the parts catalog) I would just need to snug up a couple of lock nuts. Not the case.

At some point in the car's history, a few make shift repairs occurred in order to tighten the door handle.

On the lock side, a washer and a wood screw kept it in place, along with a small glob of JB Weld.



No wonder the door handle wasn't tight. At some point the stud was broken off, drilled out and a screw put in.

On the front of the handle, I found the stud was jbwelded on, and to cover the fix and still get it to snug, a series of washers:







I tried to run an M4x.75mm die over the front post, seeing that the studs are an M4x.75



The post, of course, just snapped off.



So, I decided to drill both secure points with a 3.2mm drill bit (perfect to accept a M4x.75 bolt):



There is quite a bit of "meat" on the handle, but mind your drill depth. I drilled to a depth of 10mm in both holes.





After tapping and cleaning the holes, I ran to the hardware store and picked up two M4x.75x10mm bolts (uses a 7mm head):

[dmaddox]

Once prepped, I re-lubricated the door internals since the door card was off.

I then applied blue thread lock on both, used an M4 flat and lock washer



Using a 7mm 1/4" socket with a long extension, snugged up both bolts:





Now the handle is nice and snug, and I didn't have to bid on the expensive door handles on ebay :-)

Handle salvaged, and installed properly. I am sure I missed something - let me know, if I have.

Happy door handling.

[Jim Morris]

Nice work. Terrific photography.

[ejboyd5]

Good work and satisfying as well.

[wru]

fantastic work - great write up, thanks!