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bbade · 07-04-2010, 01:05 PM

Passenger Door Handle Repair:

Now for the infamous door handle, mine was broken by an excited passenger last summer at a track day

. There are several documented fixes for this handle, but I didn't find one that quite fit my liking.

Step 1: Clean the break area. Trim back any overhanging foam tape. It is also a good idea to trim down the break so that the Plast-Aid can really penetrate and get a good bond. I didn't get a good picture of this step, but here is a picture of the break I am working with.
DSCF4057.jpg

Step 2: Attach the two broken handle pieces to the main plastic piece; there will be two screws on the upper portion and two screws on the lower portion of the handle. Once all the plastics are together, attach them to the door panel as though you were reassembling everything; there are 6 or 7 screws. I forgot to take a picture of this step, but y'all know what the door panel looks like assembled.

Step 3: Make sure all the plastic pieces are aligned satisfactorily. Then tape some aluminum foil around the back side of the break (looking at the door panel), this is to prevent Plast-Aid from leaking through. Mask off the area around the window switch hole and place a towel or rag over the door panel to serve as a drop cloth. You want to be very careful not to drip Plast-Aid on your door panel.
DSCF4070.jpg
DSCF4069.jpg

07-04-2010, 01:05 PM	#6
bbade Rotary Fanatic Join Date: Mar 2008 Location: Macungie, PA Posts: 163 Rep Power: 18	Passenger Door Handle Repair Passenger Door Handle Repair: Now for the infamous door handle, mine was broken by an excited passenger last summer at a track day . There are several documented fixes for this handle, but I didn't find one that quite fit my liking. Step 1: Clean the break area. Trim back any overhanging foam tape. It is also a good idea to trim down the break so that the Plast-Aid can really penetrate and get a good bond. I didn't get a good picture of this step, but here is a picture of the break I am working with. DSCF4057.jpg Step 2: Attach the two broken handle pieces to the main plastic piece; there will be two screws on the upper portion and two screws on the lower portion of the handle. Once all the plastics are together, attach them to the door panel as though you were reassembling everything; there are 6 or 7 screws. I forgot to take a picture of this step, but y'all know what the door panel looks like assembled. Step 3: Make sure all the plastic pieces are aligned satisfactorily. Then tape some aluminum foil around the back side of the break (looking at the door panel), this is to prevent Plast-Aid from leaking through. Mask off the area around the window switch hole and place a towel or rag over the door panel to serve as a drop cloth. You want to be very careful not to drip Plast-Aid on your door panel. DSCF4070.jpg DSCF4069.jpg __________________ Proud owner of a base 1993 Montego Blue FD. PFC, RB single tip, Koyo Radiator, KDR rebuilt motor, polished OEM front strut bar, FEED replica sideskirts, OEM 99 spec rear spoiler, SuperPro Bushings Many thanks to Dave at KDR for sparking my rotor addiction.