stupid door handles...(outside)

[rschreiber]

So I've been using this forum for a LOT or reference stripping down my '77 to get her restored and one problem that i'm trying to fix is when I took the handles of the driver door, I sheared the stud off. I've got 5 or 6 doors to pull other handles off, but they all seem to be in the same shape on the back side. Meaning the one other I pulled broke also. The orivinal handles are in excellent shale, no pitting in the chrome and everything works well but i'm trying to figure out a way to put another stud back into the aluminum handle. if you have had this problem I'd like to hear some recommendations. At first I was going to just drill it out and weld in a stud, until I realized it was a steel stud in an aluminum cast handle. So now i'm thinking I need to put a welx pool on the remains of the stud grind it flat and the weld the new stud onto that. Sound feasible to anyone else? Or sbould I just use the old ones i got off Ebay with the rust and pitting and just refinish the chrome?

[dmwhiteoak]

man, you got lots of spiders , I haven't had my door handles off so not much help I can be. There are alot of folks on here that can help just be patiant.

[rschreiber]

Well the two 850s have half a good body each and 1 good engine so you can discount those, but the 77 is getting a full restore in my shop right now and the X is up next. I bought the 78 for a parts cat but funny enough it is the only one that runs and sorta drives.

[RRoller123]

Love those X1/9's! I must admit my '79 was the most fun car I have ever owned. If I didn't really want a full, true convertible I would probably have bought another one. They were so far ahead of their time! But I sure do love my classic Spider and the charm of a European style roadster! They are both great designs, each in their own way.

[124JOE]

when my pass side door handle broke the studs
i had it drilled out and a bolt throu to re attatch it
first the hole for a bolt
then from the out side a bigger hole for the head of bolt

ive been thinking about filling the holes with solder

hope this helps

[rschreiber]

Ok, I came up with an idea. The old handles I have are in excellent condition... Other that the studs being sheered off. I'm planning on welding to the embedded steel that's left and welding new studs to that and on the back side adding a spacer under the nut to offset the weld since I can't cut a thread all the way down to the cast metal... Any thoughts? I'm going to do it anyways and post pics but having some input could help.

[manoa matt]

I've repaired a few handles with broken studs. First grind down the remaining stud so its flush with the handle, then get a 1/6" bit and drill in the exact center. Keep drilling successively larger holes until you get to the size of the stud shank. Use the appropriate sized metric tap to tap threads into the hole. Clean the hole and the new stud well with aceone or xylene. Coat the threads in the hole with JB weld or permenant thread lock. Screw in a new bolt/screw, then cut the head off at the appropriate height. I think I might have used a stainless steel bolt and nut to prevent any future corrosion.

I thought about the welding idea but gave up as its too small, and you will only get one shot to make a proper arc and weld. If splatter or weld material gets too high up on the threads you will have issues installing a nut.