How to fix a broken passengers interior handle

[Bobbit]

A ham fisted friend of mine slammed shut the passengers door and broke the handle, so i took it all apart and came up with this.

Tools and Materials:
Sheet metal (i used steel 3mm so it was moldable but still stiff)
Tin snips (for cutting the metal)
Rivet gun and rivets
A drill and bit (the bit should be the same size as the rivets or slightly larger)
2 bolts and nuts that are the same size as the rivets

The offending handle:



as you can see the top part has snapped and this is where it screws into the door so the handle is useless.

The fix:

I cut two strip of metal that would fit to the plastic handle, note the bottom of the 1st metal strip fits inside to raise bit of plastic, i figured this would help stop and sideways movement so made sure it was a snug fit:





I then shaped the metal to the plastic and drilled 3 holes in the first strip. 1st hole where the metal would secure to the door and 2 that would secure the metal to the handle (i had the metal on the handle and drilled through the handle at the same time). I bolted the strip to the handle and then shaped the 2nd metal strip to the other side of the handle, i did this so the first strip would not move and i could see exactly where the 2nd strip need to be shaped and secured to.




Then i drilled the 2 holes through the 2nd strip.




I was left with 2 strips of metal that were shaped to the handle and i could then hold the lot together with rivets.




If you do, this rivet the other way round to the pics, i had a blond moment and put the washers on the exterior of the handle, luckly they cannot be seen but would give a better finish, on the following pic you\'ll see the rivets that I wanted on the outside. Also when riveted together the two strips over lapped each other at the top of the handle, where they screw to the dor. So i bent the edges round on the other strip so they actually added more strenght.


I then test fitted the handle with the door card off:




You will need to bend the metal to get a good fit, this was why i used 2 thin strips, as they are easy to bend on their own but when bolted together that give good rigidity.

Apologises but didn\'t take any pics of the final fitment but you\'ll all know what a passengers door handle looks like.

It\'s been 2 weeks since the repair and the handle is fine. Hope this helps any one with a knacker handle. All in this took me about 2hrs including getting the door card off and on again.

[RobbieRX-7]

This is why i ask passengers before they get in to open the door and grab the window frame, and to close the door, use the other inside handle. Doors on the fd are heavy!

[Bobbit]

I do too bud, my mates been in the car dozens of times but the tool forgot.

[D2BBA]

LOL, I thought it was just me!

"Nooo! grab the other handle!"

Chris