3j3j3j

My Driver door handle broke awhile back and I was sick of reaching through the back door to get the door open from the inside. I tore apart the door and removed the handle to find the piece of plastic On the handle that pushes down the bell crank, that pushes down the handle linkage To open the door latch, was snapped. I could have ordered a new door handle, but didn’t want to go through the hassle of finding a color matched handle or getting it painting. Instead, I found a way to fix it for free. Summary: I disassembled the handle, made a brace for the broken plastic by cutting up a washer, ground down the plastic on the door handle to fit the brace, Epoxied the brace and plastic pieces back together, and reassembled the door handle. 1. Remove door card, pull away plastic sheeting, remove handle from door. Look this up if you have too, but it’s not too hard to figure out either. 2. There is a pin going through the hinge of the handle. On one end, it looks like a nail head. On the other end, the pin is flanged. The flange is made by bending down a hollow tip on the pin. If you work around the flange bending it back upright with a pair of dikes, you can bend the entire thing inline with the rest of the pin. This takes some work, and I used some larger pliers at the end to squeeze it as round as possible. 3. Pull out the pin. I used a combination of pulling on the nail head side with pliers and pushing on it from the side that was flanged with a punch. 4. Find a large fender washer (I used 1/2 inch, but it was slightly too thick, try and find a washer that is not too thick, but has a large diameter) trace out the shape of the broken plastic onto the washer and cut the washer the size of the broken plastic. Make the piece as big as possible so that there is more surface area for the epoxy to bond them together. You can cut the washer by whatever means you have. A dremel with a cutting wheel is probably most precise and easiest, although a hacksaw would work to. I used a bench grinder to smooth the edges. 5.Narrow down the broken plastic arm so that when the washer is added, the arm plus the washer is just as thick as the arm originally was. You are removing the width of the washer from the plastic arm. I whittled away with a razor blade at first, but I found using the side of the wheel on the bench grinder was much more efficient. Just go slow and press lightly so that the plastic doesn’t get hot and start the melt. Here is a picture of the broken piece once it was narrowed 6. Rough up the washer and plastic with some sand paper. Clean it with alcohol to make a clean surface for the epoxy. 7. I used JB weld here. I first tried using some cheap 5 minute epoxy, but it was too thin and didn’t hold. Apply liberal JB weld the the washer and plastic piece so that they all fit together, and the pieces together with vice grips. Let the JB weld cure for at least 6 hours. I waited 24 just to be safe. 8. Once the JB weld cures, reassemble the door handle. 9. Once you pushed the pin back in, use a punch to flange the pin back out so that it cannot pull back out. When you strike the punch, resisting in the hollow portion of the tube, it will bend the metal you bent up in the beginning back down into a flangish shape. It will not be nearly as pretty as when it started, but it will hold. Here is a finished product. These aren’t the best instructions or pictures, but it will make a lot more sense once you have the handle out of the door and are looking at it. I am confident this repair is just as strong or stronger than the door handle originally was, but time will tell as I just threw it back together tonight... then proceeded to lock my keys in the car, but that’s another story. Credit to Maclif who made a similar door handle repair using a washer, giving me the idea.

This ^. I’ve had these bulbs on a couple cars and they are great. Sent from my iPhone using Tapatalk

Do you have a diesel outback? If so, that’s rad and if not, there is no glow plugs in a gasoline engine. If you narrow down what you are looking for a little bit someone will be able to point you in the right direction. What problem is being attempted to fix? Sent from my iPhone using Tapatalk