Help w/ replacing Door Handle Pin

[etlsport]

I would worry about any threads exposed tearing up the plastic every time the handle is used or binding up.

I like Toms idea of drilling and tapping the OEM to accept a bolt, only issue i see is that the bolt would have to be very small and could bend or break if it spans any joints. Plus the threads in the plastic.

What i would do is get a steel rod of the same diameter and cut threads into the outside of each end so you can put a nut on as a stopper. That way there are no threads under the plastic and you have the maximum diameter possible.

You could probably go even lower tech and just drill a hole at each end and put a cotter pin through to hold it in place..... Or score a grove with a pipe cutter and use a snap ring. There shouldn't be much if any lateral force on the pin, it will all be shear.

[tysamigo]

I took it to the owner of a small company that (for the lack of a better word at the moment) "plays with metal" for over 30 years including welding, making huge fancy fences, doors, artwork, etc.

We found that the Door Handle Pin is identical to one of these nails that he had (16d w/hot dipped coating of something). It's 153 Thousands of an inch and about 4 1/4" long. The nails are the same except they are not available in that length, so he's going to make a couple of pins by welding 2 nails together, painting over the weld to prevent rust, used the flat end of the nail for the pressed end, and the other he will flatten out to hold it in.

It should work... I'll keep you posted...

[tysamigo]

I would worry about any threads exposed tearing up the plastic every time the handle is used or binding up.

Yeah, this is what everyone has agreed upon

What i would do is get a steel rod of the same diameter and cut threads into the outside of each end so you can put a nut on as a stopper. That way there are no threads under the plastic and you have the maximum diameter possible.

This is the next idea, however there were a couple of bumps. The size of steel rod is so small that I would have to do some research. We called a few of the big steel companies from google searching that specialize is "smaller orders" and it's not a common size so it's a special order which would require a large order. Also the steel rods would not come coated. I would have to coat them myself. Also, the amount of space is so small (as you pointed out) that the nut would have to be TINY and effective... This can all be done, but costly and timely... but I will go this route if the first idea doesnt work (welding 2 nails together)...

[tysamigo]

I purchased 2 Steel Rods from a local steel dist., each are 12' long and are 5/32" Cold Roll. Larry (the metal guy) is going to make 2 sets of pins (one to use now and one as a back-up), however the extra rods are being pre-cut so that we can make more pins in the future.

My hope is that this will all work perfectly. If it does (and I will follow up as the project is finished) then I can offer to anyone in the group, sets of these pins.

If you ever decide to remove your door handle and have it painted, sprayed w/Linex, wrapped in CF or whatever the case may be, it is best to dissassemble the handles and if you do this, you will need a new set of pins.

I will keep you posted...