Interior Door Panel Repair Thread

bbade · 07-04-2010, 01:23 PM

Step 6: We will be using a small piece of metal to reinforce the handle. I used a piece out of an old erector set as it is very strong yet still bendable.
DSCF4079.jpg

In the above picture the metal is already bent. We want to bend the metal in such a manner that it will conform to the inner contour of the handle and allow it to be attached to the main portion of the handle with a screw. When choosing and bending your metal remember to allow for the window switch, we want to make sure it will clear the metal when everything is assembled. Perhaps a picture will provide better explanation.
DSCF4080.jpg
DSCF4081.jpg

I used a basic pan head screw, 3/4" in length, but most any screw will do. You will want to drill a hole down into the handle and then thread the fastener gently by hand with a screw driver.

bbade · 07-04-2010, 01:30 PM

Step 7: Clean the metal and surrounding area with acetone, again be careful with the acetone as the plastic will melt with prolonged exposure. Now, pile on the Plast-Aid to really strengthen the joint and secure the metal to the handle.
DSCF4083.jpg

Step 8: To finish off the handle strengthening we want to bond the backside as well. Mask off the area around the break on the backside of the handle so that no Plast-Aid will go astray.
DSCF4084.jpg

Step 9: Clean the area well with acetone, being careful not to melt the plastic, allow the acetone to evaporate. Now bond the two halves of the handle together with the Plast-Aid. Try to lay it in there real nicely to avoid extra sanding/finishing later. Allow the Plast-Aid to set up.
DSCF4086.jpg

Step 10: Now that the handle is back together and stronger than ever it is time to finish it off, make it look nice. I have 93 plastics so the rubbery finish needed to be removed. I found the best way to do this is VERY CAREFULLY with acetone. I emphasize very carefully as the acetone will eat/melt/deform the plastic. I had to sand out a few small deformities resulting from over enthusiasm with the acetone. Work in a small area at a time, rinsing with water frequently, it will not take much to remove the finish. Once the finish is removed it is time for some sanding. I used 150 grit to smooth out the Plast-Aid bond, and attempt to match it with the handle contour. Finish with 400 and 600 grit sandpaper.
DSCF4089.jpg

Continued in next post.

07-04-2010, 01:23 PM	#1
bbade Rotary Fanatic Join Date: Mar 2008 Location: Macungie, PA Posts: 163 Rep Power: 18	Passenger Door Handle Repair Step 6: We will be using a small piece of metal to reinforce the handle. I used a piece out of an old erector set as it is very strong yet still bendable. DSCF4079.jpg In the above picture the metal is already bent. We want to bend the metal in such a manner that it will conform to the inner contour of the handle and allow it to be attached to the main portion of the handle with a screw. When choosing and bending your metal remember to allow for the window switch, we want to make sure it will clear the metal when everything is assembled. Perhaps a picture will provide better explanation. DSCF4080.jpg DSCF4081.jpg I used a basic pan head screw, 3/4" in length, but most any screw will do. You will want to drill a hole down into the handle and then thread the fastener gently by hand with a screw driver. __________________ 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. Last edited by bbade; 07-04-2010 at 01:31 PM.

07-04-2010, 01:30 PM	#2
bbade Rotary Fanatic Join Date: Mar 2008 Location: Macungie, PA Posts: 163 Rep Power: 18	Passenger Door Handle Repair Step 7: Clean the metal and surrounding area with acetone, again be careful with the acetone as the plastic will melt with prolonged exposure. Now, pile on the Plast-Aid to really strengthen the joint and secure the metal to the handle. DSCF4083.jpg Step 8: To finish off the handle strengthening we want to bond the backside as well. Mask off the area around the break on the backside of the handle so that no Plast-Aid will go astray. DSCF4084.jpg Step 9: Clean the area well with acetone, being careful not to melt the plastic, allow the acetone to evaporate. Now bond the two halves of the handle together with the Plast-Aid. Try to lay it in there real nicely to avoid extra sanding/finishing later. Allow the Plast-Aid to set up. DSCF4086.jpg Step 10: Now that the handle is back together and stronger than ever it is time to finish it off, make it look nice. I have 93 plastics so the rubbery finish needed to be removed. I found the best way to do this is VERY CAREFULLY with acetone. I emphasize very carefully as the acetone will eat/melt/deform the plastic. I had to sand out a few small deformities resulting from over enthusiasm with the acetone. Work in a small area at a time, rinsing with water frequently, it will not take much to remove the finish. Once the finish is removed it is time for some sanding. I used 150 grit to smooth out the Plast-Aid bond, and attempt to match it with the handle contour. Finish with 400 and 600 grit sandpaper. DSCF4089.jpg Continued in next post. __________________ 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. Last edited by bbade; 07-17-2010 at 10:37 PM.