BlazinLow_inORE
12-19-04, 01:43 AM
Shaved Door Handles
Leave your windows down the entire time you are doing this mod so you don't lock yourself out!!!
http://www.buildyourride.com/98s10/shaveddoor4.jpg
First remove the door panel(How-to located in interior section). Then remove the rod that goes from the interior lock to the door latch (it's the top one, only the bottom one is shown in the picture). From inside the door unhook the 2 rods that run from the outside door handle to the door latch (from the door latch). See where the red arrow is, well there is a plastic plug there, remove it and behind it is one of two bolts that hold on the outside door handle. Remove that bolt and the other one about 4 inches toward the center of the door. Now you'll be able to pull out the outside door handle along with the 2 rods. Make sure that the door latch is not locked before closing the door. Remember where you popped out that little plastic plug (red arrow)? That is a great spot to mount your door popper.
http://www.buildyourride.com/98s10/shaveddoor5.jpg
This is a picture of the inside of the door. These happen to be 35lb soleniods which is a huge overkill. The soleniod is mounted directly below the latch mechanism. The kit I bought came with some long bolts and nuts. Before you get as angry as I did trying to fit a wrench inside the door to hold the nut so you can turn the bolt about 50 times to get the soleniod tight up against the door, go to the hardware store and get some new hardware. I bought some nice countersunk phillip pan head bolts, about 3/4" long with finishing washers. Then instead of the nylon nuts the kit came with, I bought wing nuts and lock washers. The reason being, that once you get the wing nut started it won't turn because the soleniod holds the wings. It works perfect. The kit comes with cable and some cable crimp clamps. Just throw these out too because getting the correct amount of tension with the cables inside your door is practically impossible. Use a coat hanger to make a connecting rod to connect the soleniod to the lever that the outside door handle rod was connected to. You can see which one it is in the picture.
http://www.buildyourride.com/98s10/shaveddoor7.jpg
Above you can see the 2 new bolts and washers along with the door popper.
http://www.buildyourride.com/98s10/shaveddoor3.jpg
There are two ways to fill the door handle. First you can cut and weld in a piece of metal the same size as the opening. The method I prefer is to cut a flat piece of sheet metal larger than the handle opening, hold it over the handle opening, then with a screw driver scratch the outline of the sheet metal into the door. Then using an angle grinder, cut out a hole staying within the lines.
Then test fit the metal piece in the hole. I use magnets to hold the piece in place while I weld. Just tack the sheet metal in. And wait for the metal to cool before making more tack welds. If you don't you'll warp the metal like I did. I was careful and still warped it, not a lot but enough to be annoying.
Leave your windows down the entire time you are doing this mod so you don't lock yourself out!!!
http://www.buildyourride.com/98s10/shaveddoor4.jpg
First remove the door panel(How-to located in interior section). Then remove the rod that goes from the interior lock to the door latch (it's the top one, only the bottom one is shown in the picture). From inside the door unhook the 2 rods that run from the outside door handle to the door latch (from the door latch). See where the red arrow is, well there is a plastic plug there, remove it and behind it is one of two bolts that hold on the outside door handle. Remove that bolt and the other one about 4 inches toward the center of the door. Now you'll be able to pull out the outside door handle along with the 2 rods. Make sure that the door latch is not locked before closing the door. Remember where you popped out that little plastic plug (red arrow)? That is a great spot to mount your door popper.
http://www.buildyourride.com/98s10/shaveddoor5.jpg
This is a picture of the inside of the door. These happen to be 35lb soleniods which is a huge overkill. The soleniod is mounted directly below the latch mechanism. The kit I bought came with some long bolts and nuts. Before you get as angry as I did trying to fit a wrench inside the door to hold the nut so you can turn the bolt about 50 times to get the soleniod tight up against the door, go to the hardware store and get some new hardware. I bought some nice countersunk phillip pan head bolts, about 3/4" long with finishing washers. Then instead of the nylon nuts the kit came with, I bought wing nuts and lock washers. The reason being, that once you get the wing nut started it won't turn because the soleniod holds the wings. It works perfect. The kit comes with cable and some cable crimp clamps. Just throw these out too because getting the correct amount of tension with the cables inside your door is practically impossible. Use a coat hanger to make a connecting rod to connect the soleniod to the lever that the outside door handle rod was connected to. You can see which one it is in the picture.
http://www.buildyourride.com/98s10/shaveddoor7.jpg
Above you can see the 2 new bolts and washers along with the door popper.
http://www.buildyourride.com/98s10/shaveddoor3.jpg
There are two ways to fill the door handle. First you can cut and weld in a piece of metal the same size as the opening. The method I prefer is to cut a flat piece of sheet metal larger than the handle opening, hold it over the handle opening, then with a screw driver scratch the outline of the sheet metal into the door. Then using an angle grinder, cut out a hole staying within the lines.
Then test fit the metal piece in the hole. I use magnets to hold the piece in place while I weld. Just tack the sheet metal in. And wait for the metal to cool before making more tack welds. If you don't you'll warp the metal like I did. I was careful and still warped it, not a lot but enough to be annoying.