RangeRovers.net Forum banner

1 - 20 of 28 Posts

·
Registered
1970-1995 Range Rover Classic
Joined
·
24 Posts
Discussion Starter #1
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:
282299


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:
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.

282301

282302

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!

 

·
Registered
Joined
·
1,009 Posts
Good fix there
I like collecting parts
Myself
 

·
Premium Member
1970-1995 Range Rover Classic
Joined
·
1,482 Posts
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:
View attachment 282299

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.

View attachment 282301
View attachment 282302
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!

If you make any more, ill take 4.


Sent from my iPad using Tapatalk
 

·
Registered
Joined
·
35 Posts
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).
 

·
Registered
Joined
·
35 Posts
Ah - sorry not an old post...I was looking at "joined" date.

I'll take at least 2 (front and rear left side) and maybe all 4 depending on price.

Please let me know - at any moment my current handle will be non-functional and it's my daily driver :)
 

·
Registered
Joined
·
12 Posts
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:
View attachment 282299

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.

View attachment 282301
View attachment 282302
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!

Yes please!
 

·
Registered
1970-1995 Range Rover Classic
Joined
·
203 Posts
Very nice! I may be interested in some. How much are you asking for them?
 

·
Registered
Joined
·
35 Posts
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 hope that helps!
 

Attachments

·
Registered
1970-1995 Range Rover Classic
Joined
·
24 Posts
Discussion Starter #11
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!
 

·
Registered
Joined
·
2 Posts
I’ll with many others and agree that it’s an old post and that I have the same problem. Are any more available ? I need two for sure.
Got any left ?
 

·
Registered
1970-1995 Range Rover Classic
Joined
·
24 Posts
Discussion Starter #13
I have a few yeah! You need left side, right side or one of each?
 

·
Registered
1970-1995 Range Rover Classic
Joined
·
26 Posts
Hello I'm also having the same problem on my 93 would like to buy a set please. thank you.
 

·
Registered
Joined
·
2 Posts
I have a few yeah! You need left side, right side or one of each?
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.
 

·
Registered
Joined
·
1 Posts
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!
Hello- I've got a '91 classic and ready to replace all 4 doors. Can you provide pricing and lead time?

Thanks!!
 

·
Registered
Joined
·
80 Posts
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!
 
1 - 20 of 28 Posts
Top