I was getting pretty frustrated with the exterior door handles on my 92 RRC, and found that replacements (typically from ebay, pulled off donor cars) were ridiculously expensive and also, did not guarantee longevity as the same problem likely could occur down the road. I have very little trust for 80s-90s pot metal parts, especially high use, high stress parts like door handles.
We've all see this before, likely:
So, I disassembled my drivers front door latch/handle, and pulled the handle out after removing a (very rusty) pivot pin. The pin has a knurled end that is pressed into the handle "cup" (black handle housing) The handle cup is aluminum I believe, the pin was regular steel. It was rusty:
I carefully took measurements of the old parts and decided to have a go at making replacements, because these are so hard to find and I can't stand having things break, likely at the worst possible time.
The replacements came out nice, and fit directly in. I made them out of stainless steel and used a straight stainless steel dowel pin. Instead of trying to press fit it into the handle cup, I use a bronze washer and locking collar to ensure the pin doesn't go sliding out. The assembly also sits into the door recess quite tightly, which also prevents the pin from moving.
Looks pretty stock!
There is an album showing the replacement of the handle and associated videos of operation etc. I have materials to build about 50 of these (they are all welded stainless, super tough) if anyone is interested in some peace of mind!
I was getting pretty frustrated with the exterior door handles on my 92 RRC, and found that replacements (typically from ebay, pulled off donor cars) were ridiculously expensive and also, did not guarantee longevity as the same problem likely could occur down the road. I have very little trust for 80s-90s pot metal parts, especially high use, high stress parts like door handles.
So, I disassembled my drivers front door latch/handle, and pulled the handle out after removing a (very rusty) pivot pin. The pin has a knurled end that is pressed into the handle "cup" (black handle housing) The handle cup is aluminum I believe, the pin was regular steel. It was rusty: View attachment 282300
I carefully took measurements of the old parts and decided to have a go at making replacements, because these are so hard to find and I can't stand having things break, likely at the worst possible time.
The replacements came out nice, and fit directly in. I made them out of stainless steel and used a straight stainless steel dowel pin. Instead of trying to press fit it into the handle cup, I use a bronze washer and locking collar to ensure the pin doesn't go sliding out. The assembly also sits into the door recess quite tightly, which also prevents the pin from moving.
There is an album showing the replacement of the handle and associated videos of operation etc. I have materials to build about 50 of these (they are all welded stainless, super tough) if anyone is interested in some peace of mind!
hmacris - I know this is an old post, but I'm interested in at least one of these if you have any. My handle looks like your picture, but worse. I'm primarily interested in the front drivers side (North America).
I was getting pretty frustrated with the exterior door handles on my 92 RRC, and found that replacements (typically from ebay, pulled off donor cars) were ridiculously expensive and also, did not guarantee longevity as the same problem likely could occur down the road. I have very little trust for 80s-90s pot metal parts, especially high use, high stress parts like door handles.
So, I disassembled my drivers front door latch/handle, and pulled the handle out after removing a (very rusty) pivot pin. The pin has a knurled end that is pressed into the handle "cup" (black handle housing) The handle cup is aluminum I believe, the pin was regular steel. It was rusty: View attachment 282300
I carefully took measurements of the old parts and decided to have a go at making replacements, because these are so hard to find and I can't stand having things break, likely at the worst possible time.
The replacements came out nice, and fit directly in. I made them out of stainless steel and used a straight stainless steel dowel pin. Instead of trying to press fit it into the handle cup, I use a bronze washer and locking collar to ensure the pin doesn't go sliding out. The assembly also sits into the door recess quite tightly, which also prevents the pin from moving.
There is an album showing the replacement of the handle and associated videos of operation etc. I have materials to build about 50 of these (they are all welded stainless, super tough) if anyone is interested in some peace of mind!
I bought and installed one of these new door handles offered by hmacris and I wanted to post an update.
The handle looks super great and I'm psyched to be able to open my door again!
This offering came at the perfect time because my drivers side handle had just started split (see photos). I bombarded hmacris with messages and I guess he figured it was easier to sell me two handles rather than getting a restraining order.
I'm not much of a mechanic, but I like to tinker and figure things out and this turned out to be pretty straightforward.
Even though my only handle problem was with my drivers side, I have this (unrelated) issue described in the youtube clip below in both my drivers side front and rear doors.
I bought handles for both (front and rear) figuring I had to pull the door apart anyway and this way they would perfectly match. I haven't yet done the rear door...in truth they look so similar that I doubt anyone would notice. If anything the old one (which is not broken) looks lousy because you can see that the aluminum isn't exactly flat.
Anyway, if anyone is considering it I would definitely recommend them. I'm sure over time I'll replace all my handles with these.
Full disclosure - I don't know the seller at all and I paid for my handles just like anyone else would.
I have both left and right sides in small quantities now, as well as the option to do black powder coat for Discovery. If interested you can PM, will eventually get them up online for quick ordering. Thanks everyone and Happy New Year!
Need one of each now. Once I get into It and see how hard it is, I might replace them all since it’s such a common break. My front passenger door looks exactly like the picture you posted.
Let me know about price and the easiest way to get payment to you.
thanks.
I have both left and right sides in small quantities now, as well as the option to do black powder coat for Discovery. If interested you can PM, will eventually get them up online for quick ordering. Thanks everyone and Happy New Year!
What I was quoted:
Set of 2 is $180 in stainless and $215 in powder coat black. They come with all the hardware in the pictures, all stainless as well!
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