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Posted by: ripper911 Dec 10 2011, 09:55 AM

I am about to get working on my outer door handles. They both broke on the same day right before leaving to petit le mans, but in different ways.

On the drivers side I think it's the little plastic piece on the inside.
On the passengers side the handle is loose due to the plate breaking.
I have a new little plastic thingey and a new metal base for the other handle.

Anyone with experience that is willing to offer any tips or suggestions will be rewarded in their next life.

Posted by: Mark Henry Dec 10 2011, 10:03 AM

The plastic thing you can buy. The plate I made a small 3/16ths metal piece tapped and with a groove, that looks stock, but clamps the plate down with the stock bolt.

I think it's URY914 that repairs these for low cost.

Posted by: pete-stevers Dec 10 2011, 10:19 AM

Paul will fix em.. ( ury914)

Posted by: URY914 Dec 10 2011, 11:32 AM

You rang?

Posted by: ruby914 Dec 10 2011, 11:45 AM

You may have broken yours the same place that I did mine.
I made a little steel clamp and used a nut and bolt.
It took a drill, hack saw, little file work and bending a joggle.
Works great.


Attached image(s)

Posted by: ThePaintedMan Dec 10 2011, 12:01 PM

Niiiiccee!

Posted by: dangrouche Dec 10 2011, 12:03 PM

the driver side one should not involve drilling of any metal; I got one from Rich at High Performance House, Redwood city, CA and Rich told me that you cut off the old one with a pair of dykes. then you put some grease on the metal. while the handle is flexed and held open you take the new plastic piece and "load" it on. The plastic piece I had had sort of a diamond point whereas if you comparethe new one to the old one, you will see the pivot point is rounded. For the other door handle, if you have the replacement kit, which woudl conisist of the handle and a metric nut and bolt, you would drill out the old one. take a photo of the handle BEFORE taking it apart so you can see how the spring is loaded onto the assembly. Sorry no pics but when you take it apart you will see what I mean. good luck

Posted by: URY914 Dec 10 2011, 12:14 PM

Using sheet metal is OK until it rusts and runs down your door. I've been doing this since I first fixed the one I broke in college. And that was a long time ago.

Posted by: URY914 Dec 10 2011, 12:18 PM

This is an old picture of the first one I fixed on my car. I use stainless steel nuts and bolts now,

Posted by: ThePaintedMan Dec 10 2011, 12:26 PM

If you keep posting pictures I'm gonna get OCD and end up trying to do it myself Paul! Then I'll never end up coming to Tampa to see your car. Seriously, now I see how you've done it. Seems feasible. Just time consuming.

Posted by: ripper911 Dec 10 2011, 12:38 PM

I already have the parts, I'm pretty much just wondering if there is anything out of the ordinary that y'all have encountered that might pop up.

I think I'll re-key the passenger side while I'm doing this, as I understand it's fairly straight forward, swap out the little things that stick in the lock cylinder until the key works, right?

Maybe I'll send the next ones to Paul, but I am planning on fixing them this weekend so I can continue driving the car without much delay.

Posted by: URY914 Dec 10 2011, 01:07 PM

George, when you coming over? Call me on my cell, I sent you the number in the PM.

Posted by: URY914 Dec 10 2011, 01:10 PM

Ripper, be careful not to break the flapper part of the handle when putting it back together. The spring makes it tough to get the bolt back in through the holes. I reuse the original pin on my repairs.

Posted by: ripper911 Dec 11 2011, 04:49 AM

All went well, I got the handles fixed yesterday without any problem, and without any of my repair manuals.

Today is tune-up day.

Posted by: rfuerst911sc Dec 11 2011, 05:06 AM

Paul did his repair on both of my door handles and they work great. If anyone is on the fence on this one it's a no brainer send them to Paul. You won't regret it and they'll probably outlast the car .

Posted by: URY914 Dec 11 2011, 11:58 AM

Thank you kind Sir. I'm blushing.

Posted by: flash914 Dec 11 2011, 11:21 PM

While you are at it fix the root of the problem---the latch unit needs to be removed from the door and cleaned and lubed or the plastic part will bend again.

Posted by: bryanf Dec 15 2011, 12:02 PM

I agree...as long as you have the door apart, pull the mechanism and clean it really well, lube it, inspect it for any bent of loose parts. Last one I fixed the rivet that holds the pivot for the release mechanism had loosened and the mechanism was binding...a couple taps with a hammer and a little lube and it works like new.

Posted by: ripper911 Dec 15 2011, 12:11 PM

The drivers side handle is smooth as a greased midget, but I may have to do a little more to the passenger door handle.

Posted by: URY914 Dec 15 2011, 12:59 PM

Passenger side gets broken more often actually. Lack use and then you get some Bozo that rips the door open like it weighs as much as an American car door. Then they get in and slam it and weld it shut.

Posted by: rdauenhauer Dec 15 2011, 04:51 PM

Why not a nut & bolt arrangement? How do you re-use a peened alum rivit?

Posted by: URY914 Dec 15 2011, 06:35 PM

1. The pin is steel and not aluminum.
2. The orginal pin fits in the hole like it was was made for it. And it was.
3. A bolt is not the correct diameter. Which means a sloppy action.
4. The threads on a bolt will over time gall the povit surface of the handle.

Now the repair bolt that AA sells for thier replacement flapper is better than a standard bolt because it has a large shoulder and few threads. But still not as good as the original pin.