Replairing Outside Door Handle on 26-27

[ModelTWoods]

I have an improved car outside door handle with a broken, rusted spring behind the escutcheon plate. Taking it apart to replace the broken spring was easy, I just had to grind/file the crimped shoulders behind the spring retainer to remove the retainers and the broken spring from the square shaft. Putting it together is easy until it comes to crimping the square shaft behind the spring retainer so everything stays in place. I do not have access to a press or a heat torch to help make the crimps, and trying to hold the square shaft in a bench vise while smacking a chisel with a mechanics ball peen hammer, is almost impossible (I tried). anyone got any suggestions?

[varmint]

Maybe tack welds?

[ModelTWoods]

Maybe tack welds?

Vern, I had thought of that, but in addition to not having access to a press or a torch, I don't have personal access to an electric welder and because of my pacemaker, I can't weld, anyway. I'll just have to find a local welder.

[Mike Silbert]

Is there a club member near you that can help?
Someone in your local chapter?
I would fix it no charge for you, but I am 1600 miles away.
Helping each other is one of the benefits of the club.

Mike

[varmint]

I'm 542 miles on I-10 and would do it for free.
Maybe someone's closer.

[Jerry VanOoteghem]

I have an improved car outside door handle with a broken, rusted spring behind the escutcheon plate. Taking it apart to replace the broken spring was easy, I just had to grind/file the crimped shoulders behind the spring retainer to remove the retainers and the broken spring from the square shaft. Putting it together is easy until it comes to crimping the square shaft behind the spring retainer so everything stays in place. I do not have access to a press or a heat torch to help make the crimps, and trying to hold the square shaft in a bench vise while smacking a chisel with a mechanics ball peen hammer, is almost impossible (I tried). anyone got any suggestions?

Can you post a photo of the area of concern?

[ModelTWoods]

I have an improved car outside door handle with a broken, rusted spring behind the escutcheon plate. Taking it apart to replace the broken spring was easy, I just had to grind/file the crimped shoulders behind the spring retainer to remove the retainers and the broken spring from the square shaft. Putting it together is easy until it comes to crimping the square shaft behind the spring retainer so everything stays in place. I do not have access to a press or a heat torch to help make the crimps, and trying to hold the square shaft in a bench vise while smacking a chisel with a mechanics ball peen hammer, is almost impossible (I tried). anyone got any suggestions?

Can you post a photo of the area of concern?

Jerry, I'm not sure what good posting a picture of the handle will do, but here you go. The square shaft was originally crimped in the area where the vise grips are attached holding the spring and retainer in proper place. One small bead of weld on two opposite sides of the shaft would also hold things in place. A local club member has done welding for me in the past, But I feel guilty asking him for so many favors.

[Jerry VanOoteghem]

I have an improved car outside door handle with a broken, rusted spring behind the escutcheon plate. Taking it apart to replace the broken spring was easy, I just had to grind/file the crimped shoulders behind the spring retainer to remove the retainers and the broken spring from the square shaft. Putting it together is easy until it comes to crimping the square shaft behind the spring retainer so everything stays in place. I do not have access to a press or a heat torch to help make the crimps, and trying to hold the square shaft in a bench vise while smacking a chisel with a mechanics ball peen hammer, is almost impossible (I tried). anyone got any suggestions?

Can you post a photo of the area of concern?

Jerry, I'm not sure what good posting a picture of the handle will do, but here you go. The square shaft was originally crimped in the area where the vise grips are attached holding the spring and retainer in proper place. One small bead of weld on two opposite sides of the shaft would also hold things in place. A local club member has done welding for me in the past, But I feel guilty asking him for so many favors.

Terry,

I thought that a photo might help to suggest an alternate method of fixing the retainer in place. If you feel it wouldn't help, then you can skip it. No problem.

[ModelTWoods]

Can you post a photo of the area of concern?

Jerry, I'm not sure what good posting a picture of the handle will do, but here you go. The square shaft was originally crimped in the area where the vise grips are attached holding the spring and retainer in proper place. One small bead of weld on two opposite sides of the shaft would also hold things in place. A local club member has done welding for me in the past, But I feel guilty asking him for so many favors.

Terry,

I thought that a photo might help to suggest an alternate method of fixing the retainer in place. If you feel it wouldn't help, then you can skip it. No problem.

Jerry, I've tried resizing the picture that I took with my cell phone, so many times that I'm now cross eyed. I give up. Sorry, can't post picture.

[Jerry VanOoteghem]

Jerry, I'm not sure what good posting a picture of the handle will do, but here you go. The square shaft was originally crimped in the area where the vise grips are attached holding the spring and retainer in proper place. One small bead of weld on two opposite sides of the shaft would also hold things in place. A local club member has done welding for me in the past, But I feel guilty asking him for so many favors.

Terry,

I thought that a photo might help to suggest an alternate method of fixing the retainer in place. If you feel it wouldn't help, then you can skip it. No problem.

Jerry, I've tried resizing the picture that I took with my cell phone, so many times that I'm now cross eyed. I give up. Sorry, can't post picture.

Terry,

No problem. Is there enough room in there to drill a very small hole and install a tiny roll pin or dowel? Obviously, nothing large enough to weaken the shaft.

[ModelTWoods]

Terry,

I thought that a photo might help to suggest an alternate method of fixing the retainer in place. If you feel it wouldn't help, then you can skip it. No problem.

Jerry, I've tried resizing the picture that I took with my cell phone, so many times that I'm now cross eyed. I give up. Sorry, can't post picture.

Terry,

No problem. Is there enough room in there to drill a very small hole and install a tiny roll pin or dowel? Obviously, nothing large enough to weaken the shaft.

Jerry, that's a good idea, but the square shaft is only 1/4" square, and any drilled hole larger than 1/16" would probably weaken the shaft to the point durability would probably become a problem.

[Jerry VanOoteghem]

Jerry, I've tried resizing the picture that I took with my cell phone, so many times that I'm now cross eyed. I give up. Sorry, can't post picture.

Terry,

No problem. Is there enough room in there to drill a very small hole and install a tiny roll pin or dowel? Obviously, nothing large enough to weaken the shaft.

Jerry, that's a good idea, but the square shaft is only 1/4" square, and any drilled hole larger than 1/16" would probably weaken the shaft to the point durability would probably become a problem.

A 1/16" or smaller hole is what I had in mind.