Fix for aftermarket interior door handles

Discussion in 'Interior Restoration' started by mrluckies, Jun 23, 2019.

  1. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    I bought new interior door handles for my car. After reading reviews on multiple websites, it seems all of them have the same problem: the handle wobbles on the pivot.

    Since I didn’t have door handles for these doors, I needed something and had to buy them anyway.

    After getting them, I realized the hole in the handle lever is too big for the pivot. So I decided to make a bushing for them.
     
  2. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    508FEE51-6C23-475B-83C1-99D420039498.jpeg D221128F-40E2-487D-9940-A45178872216.jpeg In these two pics, you can see how much the lever wobbles.( It’s the same handle)
     
  3. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    B1F53117-ECD8-4039-8D5D-04079374D64B.jpeg 6B9C9DFF-1A60-4845-8DDE-A2EC45E1F761.jpeg I ground the rivet end off (making sure to leave as much length to the pivot as possible so I could weld it on later)
     
    Last edited: Jun 23, 2019
  4. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    I measured the pivot which is close to 1/4”. I also measured the hole of the lever which you can see is way too big at 0.294” (as opposed to the 0.245” pivot) C09179A5-16F8-4E95-B0E4-16336D08ADA2.jpeg A58B641F-4315-4163-8509-9F6850B10337.jpeg
     
    Last edited: Jun 23, 2019
  5. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    I had some 1/4” steel fuel tubing and measured the inside and outside diameters. Obviously the inside is 1/4”. The outside is about 5/16”. Bigger than the lever hole diameter, which isn’t a problem because I can drill it out.

    Note: the 1/4” inside diameter is after I cleaned up the cut end with a 1/4” drill bit. Using a regular tubing reamer didn’t get it all the way cleaned up and made it hard to fit the pivot.

    I have an old drill chuck that I put the drill bit in and use it to turn the bit by hand. I would NOT try to do this with a power drill.
    . FEB146AE-C68E-4700-AC2E-88F1FEB44FDC.jpeg 47424E18-9EA3-4D70-8F03-934174B7028D.jpeg
     
  6. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    I then opened the hole on the lever with a 5/16 drill bit. Make sure to do this perpendicular to the lever! (You can see on my top pick I messed up a little on this one. I fixed it on the passenger side better)

    As you can see, the fuel tubing goes through the lever and the pivot fits in the fuel tubing.

    (Note: the right thing to do would be to make the bushing out of slightly softer material than the lever so it wears as opposed to the lever, but I think for how much it gets moved, it should be ok. The copper tubing I had is 1/4” outside diameter which wouldn’t work since I need 1/4” inside diameter to fit the pivot pin)

    I cut the tubing to the width of the lever and put it in. The tubing is a snug fit in the lever. I had to push it in. 97B12953-4073-43FB-8BAC-99B3501A7440.jpeg 1430C52E-12A6-4F38-A164-D0E2E7B1C816.jpeg C6CD304F-E319-4564-B51A-52530EE37FCB.jpeg
     
    Last edited: Jun 23, 2019
  7. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    I then reassembled the handles and put a tack weld on the end of the pivot. If you left the pivot as long as possible and don’t have access to a welder, you might be able to stake the pivot. The spring will likely have enough pressure on the pivot to keep it from slipping out of you install the pivot from the top down.

    Or if you bought 1/4” all thread or really long screws they might work as well. E3602A12-2141-45FC-A63D-D9291C7BDE82.jpeg 80A0B556-4A46-40EB-9B66-46744011632E.jpeg
     
  8. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    972689A8-3A88-4076-B062-8E5FB29C0FF2.jpeg CE3BBE92-E813-4503-8D53-75B29258D17D.jpeg Before installing, I also noticed the hole where the pull rod goes on was too small, so I opened them up with a 11/64” drill bit. Now it works smoothly and doesn’t wobble!

    (Here you can see the old drill chuck I use to turn drill bits by hand)
     
  9. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    Don’t forget to install the pull rod retaining clip before putting the handle in the door!

    My handles didn’t come with them. I found a pack of 50 on eBay for $7 shipped!

    I hope this fix helps others! I hated the wobble on my levers and didn’t have any other option but to try and fix them.
    0D6E1EE1-01FF-4A25-A899-892C459D0E7B.jpeg A1642F25-5E88-4392-8038-F6159608A5CD.jpeg
     
  10. mrluckies

    mrluckies Veteran Member Lifetime Gold Member

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    Make sure to measure you own stuff before trying as you may have different dimensions if your parts were made by someone else!
     
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