inside door handle Mondial 8

I broke 2 in my mondial, right hand inside handle, I got some 5mm aluminium and welded a piece of 3mm aluminium down the centre, then shaped the handle and the little bit under the handle that holds the cable that opens the door, for a total of a couple of hours of my time and $50 for the material and someone to weld it for me, even in a concours event no one picked it as non genuine and it is much stronger and wont break

 

Hi, Alan,

Some pictures wanted please !! So we can see how you did it....

Guido

 

I dont have any photos of the during process, but here is how I did it,
I went to a local cylinder head shop (you could go to any aluminium welding shop) and looked through their scraps bin for a piece of 3mm aluminium plate a little larger than the handle and a piece of 5mm aluminium plate for the lever part under the handle, I had them weld the 5mm plate under the 3mm plate, this cost me $50,
in the first pic, I cut off the part of the handle that pushes the opening lever and used it as a template on the new handle (before I cut it off I took a couple of measurements to get the correct position,
then with a hack saw, flies and a die grinder (dremel) I shaped the lever under the handle, drilled the hole and test fitted in the handle assembly, made fine adjustments to get it working right,
then in the next pic I had to use some small washers to 'widen' the lever where it fits into the handle assembly, this was to stop the new handle from moving side to side,
once it was fitted and working perfectly I removed it and traced the shape of the handle on the top, cutting it to size and using a bench grinder I rounded the corners off and test fitted again, then some more filling untill the fit was right, using some wet and dry sand paper to smooth the top and corners and until I was happy with the look,
then refitted the whole lot back together and now I have a handle that wont break, and didnt cost an arm and a let to fix
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login

 

I know of two I have been birdogging.
If i can get them i want $ 100.00 each.
Psssssssst,,,,,Try to get one from a 400i, like me......!)
& Don't throw the broken one away.

Depending on where it is broken,, a right can be turned into a left and vise versa..

Ciao,
Edwardo

 

Very nice job...something to put in the Mondial repair section, dont you think ?

Greetings, Guido