It’s all going wrong !!!

[Mazza]

Firstly , the clutch on my 1.9 has been slipping and slowly getting worse … but having got all the parts as recommended by @Lee was going to have a day up in Basingstoke and sit back drinking tea, while I watch with total admiration while Lee , Gaz, Hollie, Rob and who ever else turns up on the day, fix my car ….

But the car over the last week has got so bad don’t think it would make the journey to Basingstoke, so first garage I went to saying what I needed doing and have all the parts ….not interested … unless they supply the parts ( probably at 100% mark up !!!) .

Found another guy who was recommended, and happy to do it using my parts, if I could leave it for a couple of days. Just so he could work round other jobs he was doing.
Price quoted was fair enough, so going in tomorrow and back on Friday.

Then went to the post office in the 2.8!…. shut the drivers door and the handle snapped !!!!

So already gave the door card off found most of the bits of plastic and getting them superglued back together. Might get some two part epoxy to strengthen the joints.

Bottom of the handle cracked and out of alignment

This was still attached to the door

The black melted rivet by the square in the opening had snapped

Two bits had to be superglued back into position

used a screwdriver to realign the metal insert under the plastic

once realigned … superglue and a vice to hold it

The black ‘dot’ is where the rivet snapped… may be able to drill a small hole in the centre and use a self tapper, or drill it out and bond in a rivnut… ( haven’t decided yet )

waiting for glue to hold , but will go and get the two part epoxy now and try to bond it all back together…

Watch this space !!!

 

[Scooblitz]

Ahhh…It’s never easy owning an old car.

The ‘retro-cool vibe ‘ does come with its downfalls. Should that be doorfalls.

 

[1955Davidr]

My door handle did the same a few years back, superglue and two part epoxy did the trick and still holding well. I also fitted VW T5 pull handles on the upper part of the both doors just in case, but always forget to use them!

 

[Kenhayes247]

My door handle did the same a few years back, superglue and two part epoxy did the trick and still holding well. I also fitted VW T5 pull handles on the upper part of the both doors just in case, but always forget to use them!

I am surprised nobody on the forum has 3d printed a door handle, especially as the older the handle gets the more brittle it becomes, and the cost of an original - some people ask silly money!

These do L and R but would need to have the leather applied. I haven’t tried them by the way, just something I found whilst browsing.

https://ebay.us/m/TYAGUe

 

[Mazza]

After superglue and epoxy were dry I looked at how to create the fixing…. Started by drilling a 3mm hole in the centre of where the plastic rivet had been … this fortunately is a solid piece of plastic , so measured the self tapping screw and drilled it out to 4mm and only deep enough to take the screw.

top left fixing hole is where the self tapper will screw into the handle.
bottom right two holes that hold the bottom of the handle. Note only one has a washer (???) which is under the handle

reverse side has a plate and the two screws

so screwed the handle back on and the new self tapper worked ok.

Handle back on , seems ok and I could pick the door card up with it and seems solid enough. But will leave overnight ( the heating is off so the rad wont get hot ) and make sure the adhesives are all cured.

It doesn't quite line up but that could be due thickness of the epoxy resin I had to use……but it not really an issue.

Will put the door card back on tomorrow after I get back from dropping the 1.9 off to have the clutch done.

 

[Synclare]

That towel has seen better days too Malc

 

[Mazza]

Back in the car and doesn’t look too bad …. Time will tell if it was a successful fix

 

[Ianmc]

Good luck with the repair. I "repaired" mine a couple of times but it did not last long. Resorted to purchasing a new one in the end at significant cost.

 

[the Nefyn cat]

So, you managed to get superglue to stick the bits you wanted to stick, and not just your fingers? Any idea what brand it was? I may give it a try.

 

[Lee]

Good effort Malc, I have two sets of door cards I need to dispose of in the shed. Was going to ping you a couple photos.

 

[Mazza]

So, you managed to get superglue to stick the bits you wanted to stick, and not just your fingers? Any idea what brand it was? I may give it a try.

I used the Loctite ( Robert Dyas) to piece all the bits of plastic back together so it all lined up and then mixed up the epoxy ( B&Q) to fill all the gaps and go over the joins that had been glued and to strengthen the areas that had been damaged.

 

[AntStark]

I used specific loctite plastic glue and also reinforced with the plastic welder.

 

[Mazza]

Doh …. now you tell me. !

 

[1955Davidr]

My T5 “assisters”

 

[AntStark]

Doh …. now you tell me. !

I will refer the gentleman to his response to my earlier post on the matter

How To Guide - Fixing my drivers door pull

Ever since I bought my Zed I knew I needed to sort my door pull. It wasn’t bolted on ! it was literally just glued to the door card..and quite badly at that. The recent inclement weather gave me an excuse to do this indoors. The door card popped off with no damage and revealed the vapour...

zroadster.org

 

[the Nefyn cat]

I used the Loctite ( Robert Dyas) to piece all the bits of plastic back together so it all lined up and then mixed up the epoxy ( B&Q) to fill all the gaps and go over the joins that had been glued and to strengthen the areas that had been damaged.
View attachment 361967

Damn. I tried the Loctite stuff a while ago and it just stuck my fingers together, I may try some of the plastic-specific type next time.

 

[Guinn]

Firstly , the clutch on my 1.9 has been slipping and slowly getting worse … but having got all the parts as recommended by @Lee was going to have a day up in Basingstoke and sit back drinking tea, while I watch with total admiration while Lee , Gaz, Hollie, Rob and who ever else turns up on the day, fix my car ….

But the car over the last week has got so bad don’t think it would make the journey to Basingstoke, so first garage I went to saying what I needed doing and have all the parts ….not interested … unless they supply the parts ( probably at 100% mark up !!!) .

Found another guy who was recommended, and happy to do it using my parts, if I could leave it for a couple of days. Just so he could work round other jobs he was doing.
Price quoted was fair enough, so going in tomorrow and back on Friday.

Then went to the post office in the 2.8!…. shut the drivers door and the handle snapped !!!!
View attachment 361813


So already gave the door card off found most of the bits of plastic and getting them superglued back together. Might get some two part epoxy to strengthen the joints.
View attachment 361815View attachment 361817

Bottom of the handle cracked and out of alignment
View attachment 361819

This was still attached to the door
View attachment 361821

The black melted rivet by the square in the opening had snapped
View attachment 361823

Two bits had to be superglued back into position
View attachment 361825

used a screwdriver to realign the metal insert under the plastic
View attachment 361827

once realigned … superglue and a vice to hold it
View attachment 361829

The black ‘dot’ is where the rivet snapped… may be able to drill a small hole in the centre and use a self tapper, or drill it out and bond in a rivnut… ( haven’t decided yet )
View attachment 361831

waiting for glue to hold , but will go and get the two part epoxy now and try to bond it all back together…

Watch this space !!!

The handle on .driver side door of my 1.9 broke. Slapped some gorilla glue on it drilled a couple of holes and screwed it back together. So far it's holding nicely.

 

[Mazza]

It’s been over a month since I did mine and so far so good