fryhover65
Member
- Joined
- December 22, 2009
- Messages
- 13
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- City, State
- inola,oklahoma
- Year, Model & Trim Level
- 94 sport
where should i start in shaving my door handles on a 1st gen sport?
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shaved door handles
- Thread starter fryhover65
- Start date
Spdrcer34
Explorer Addict
- Joined
- March 14, 2002
- Messages
- 3,873
- Reaction score
- 13
- City, State
- Bremerton, WA
- Year, Model & Trim Level
- 1992 Explorer XL
You should start by taking the door panel off. You will also need to temporarily pull the interior handle too. then remove the door latch assembly. Remove the latch rods that actuate when the outside door handle is lifted.
Remove the lock rods (yes BOTH of them) too. Pull the clip that holds the outside lock in place. Remove the Lock Cylinder.
From the outside of the vehicle, drill out the 2 rivets that hold the handle to the door.
Remove the door handle.
Weld in a piece of steel to cover the depression in the door, and lock hole. GO SLOW. You WILL WARP THE DOOR PANEL IF YOU DON'T. As you go around the perimeter of the panel, if you can't touch the are you are about to weld.....DON'T WELD IT. Don't use anything to speed up the cooling process.
It took me about 1 hour per side JUST TO WELD IT...
Grind the welds downs.
Hammer any high spots in the new panel.
Apply body filler.
Sand.
Apply more body filler.
Sand.
Apply more body filler.
Sand.
Sand.
Apply glazing compouund.
Sand.
Primer.
Sand.
Sand.
Primer
Sand.
Paint.
Ryan
Remove the lock rods (yes BOTH of them) too. Pull the clip that holds the outside lock in place. Remove the Lock Cylinder.
From the outside of the vehicle, drill out the 2 rivets that hold the handle to the door.
Remove the door handle.
Weld in a piece of steel to cover the depression in the door, and lock hole. GO SLOW. You WILL WARP THE DOOR PANEL IF YOU DON'T. As you go around the perimeter of the panel, if you can't touch the are you are about to weld.....DON'T WELD IT. Don't use anything to speed up the cooling process.
It took me about 1 hour per side JUST TO WELD IT...
Grind the welds downs.
Hammer any high spots in the new panel.
Apply body filler.
Sand.
Apply more body filler.
Sand.
Apply more body filler.
Sand.
Sand.
Apply glazing compouund.
Sand.
Primer.
Sand.
Sand.
Primer
Sand.
Paint.
Ryan
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