 Problem: loose stud on door handle, More problems |
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| bbrock |
 Jul 10 2017, 04:30 PM
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#1
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914 Guru  Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains 
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Hoping to get some BTDT wisdom. I'm simply trying to remove the passenger side door handle and hit a major snag. The little M6 stud that attaches to the tab on the outer part of the handle is just spinning free so I can't get the self-locking nut off.
(IMG:http://www.914world.com/bbs2/uploads_offsite/cdn4.pelicanparts.com-20845-1499725820.1.JPG) It isn't broken, it is still attached to the tab on the door handle, but loose inside. I've tried soaking the nut with PB Blaster, heating it with a propane torch, and trying to wedge a flat blade screw driver against the stud in an attempt to create more friction resisting the stud turning than needed to break the nut loose. There isn't a lot of room in there to work and I know from sad experience how easy it is to break the pot metal on these things. The only options I see now involve a drill and destroying the stud, or drilling in from the outer (tab) side to try to pin the stud enough to get the nut off. Either way, I need to make sure there is a path forward for a good repair. Even better would be the third option that you are going to tell me about (IMG:style_emoticons/default/smile.gif) |
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| mepstein |
Jul 10 2017, 04:41 PM
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#2
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914-6 GT in waiting Group: Members Posts: 19,640 Joined: 19-September 09 From: Landenberg, PA/Wilmington, DE Member No.: 10,825 Region Association: MidAtlantic Region
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Can you dremel off the nut?
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| bbrock |
Jul 10 2017, 04:59 PM
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#3
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains
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QUOTE(mepstein @ Jul 10 2017, 04:41 PM)  Can you dremel off the nut? I thought about that. I'm not confident I have the skill to dremel off the nut without nicking the threads. Or are you suggesting to gut the stud off behind the nut? That would be doable if there is a good way to attach a new stud. |
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| arne |
Jul 10 2017, 05:54 PM
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#4
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Serial Rescuer of old vehicles... Group: Members Posts: 770 Joined: 31-January 17 From: Eugene, Oregon Member No.: 20,799 Region Association: None |
If the stud is spinning, it has a problem and there's no reason to worry about damaging it. It will need to be replaced anyway, perhaps with an oversized stud. I believe that someone here on World can repair these handles.
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| Specracer |
Jul 10 2017, 07:38 PM
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#5
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Member Group: Members Posts: 100 Joined: 27-March 17 From: SE Mass Member No.: 20,970 Region Association: None |
im dealing with the same issue. I'll be cutting the nut off. Once I get it apart, hoping to fix the stud with a bonding adhesive.
One solution I read about here, is a flat head screw (head exposed on the outside). |
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| bbrock |
Jul 10 2017, 07:49 PM
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#6
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains
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QUOTE(Specracer @ Jul 10 2017, 07:38 PM) im dealing with the same issue. I'll be cutting the nut off. Once I get it apart, hoping to fix the stud with a bonding adhesive. One solution I read about here, is a flat head screw (head exposed on the outside). That could work (IMG:style_emoticons/default/beerchug.gif) I would think good old JB Weld would hold it tight. Does anyone know how these things are attached at the factory? Looking at my good one, It kind of looks like the stud has a button head that was press fit into the tab prior to plating. But I can't really tell for sure. |
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| GaroldShaffer |
Jul 10 2017, 07:53 PM
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#7
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You bought another 914? Group: Benefactors Posts: 7,628 Joined: 27-June 03 From: Portage, IN Member No.: 865 Region Association: None 
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The only way I have ever been able to get them off when the stud spins is to cut the nut & stud off. I hate doing that, but I really don't see any other option. Once off you can drill out the stud then use a small nut & bolt for re-install. while not 100% for concourse cars it will work for a daily type driver. My 70 had that fix on the passenger side for over 10 years before I went ahead and replaced the complete handle with anon broken stud.
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| jmalone |
Jul 10 2017, 08:48 PM
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#8
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Member Group: Members Posts: 119 Joined: 3-July 09 From: reno,NV Member No.: 10,529 Region Association: Northern California
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I cut off the stud or nut and then used a SS button head screw that I sourced from Lowes. I tapped the handle and used Locktite on the new screw. ( Lowes has a good fastener selection ) (IMG:style_emoticons/default/smile.gif)
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| URY914 |
Jul 10 2017, 08:59 PM
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#9
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I built the lightest 914 in the history of mankind. Group: Members Posts: 124,157 Joined: 3-February 03 From: Jacksonville, FL Member No.: 222 Region Association: None |
QUOTE(arne @ Jul 10 2017, 04:54 PM) I believe that someone here on World can repair these handles. That would be me. (IMG:style_emoticons/default/biggrin.gif) Cut off the stud/nut. Remove the handle. Drill the out stud. Replace the stud with a bolt or counter sink a screw. If (or when) you break the mounting tab off when doing this, send it to me and I'll replace the tab. |
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| bbrock |
Jul 10 2017, 09:59 PM
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#10
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains
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QUOTE(URY914 @ Jul 10 2017, 08:59 PM) QUOTE(arne @ Jul 10 2017, 04:54 PM) I believe that someone here on World can repair these handles. That would be me. (IMG:style_emoticons/default/biggrin.gif) Cut off the stud/nut. Remove the handle. Drill the out stud. Replace the stud with a bolt or counter sink a screw. If (or when) you break the mounting tab off when doing this, send it to me and I'll replace the tab. That's what I'm looking for! A backup plan to my inevitable screw up. Thanks. |
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| bandjoey |
Jul 10 2017, 11:12 PM
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#11
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bandjoey Group: Members Posts: 4,930 Joined: 26-September 07 From: Bedford Tx Member No.: 8,156 Region Association: Southwest Region |
Cut a slot on the end for a small blade screwdriver to hold the stud
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| GaroldShaffer |
Jul 11 2017, 07:57 AM
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#12
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You bought another 914? Group: Benefactors Posts: 7,628 Joined: 27-June 03 From: Portage, IN Member No.: 865 Region Association: None
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QUOTE(bandjoey @ Jul 11 2017, 12:12 AM) Cut a slot on the end for a small blade screwdriver to hold the stud (IMG:style_emoticons/default/slap.gif) Now why didn't I think of that next time I have that problem I'm going to try this. (IMG:style_emoticons/default/smilie_pokal.gif) |
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| bbrock |
Jul 11 2017, 02:47 PM
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#13
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains
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QUOTE(Garold Shaffer @ Jul 11 2017, 07:57 AM) QUOTE(bandjoey @ Jul 11 2017, 12:12 AM) Cut a slot on the end for a small blade screwdriver to hold the stud (IMG:style_emoticons/default/slap.gif) Now why didn't I think of that next time I have that problem I'm going to try this. (IMG:style_emoticons/default/smilie_pokal.gif) That sounds like the ticket. I won't be able to mess with it for at least a week, but will report back. Thanks for the tip! (IMG:style_emoticons/default/thumb3d.gif) |
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| colingreene |
Jul 11 2017, 04:36 PM
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#14
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Senior Member Group: Members Posts: 731 Joined: 17-October 13 From: Southern California Member No.: 16,526 Region Association: Southern California |
I have a ton of spare door handles if you happen to go that route after you cut it off.
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| bbrock |
Jul 21 2017, 04:25 PM
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#15
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains
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QUOTE(colingreene @ Jul 11 2017, 04:36 PM) I have a ton of spare door handles if you happen to go that route after you cut it off. Out of curiosity, what would you want for a right side? Last night I got a change to try the slot method. It was easy to cut a slot with a dremel and cutoff wheel just right to slip a flat blade screwdriver into. Should have worked perfectly - but didn't. (IMG:style_emoticons/default/headbang.gif) I couldn't hold the screwdriver tight enough to get the nut to budge. I ended up slicing the stud lengthwise all the way down to cut the nut in half. Mine was rusted just enough to make the slot trick not work. Still, I think that is the way to go. Had it worked, the stud would have still been perfectly serviceable once something was done to keep it from spinning. But the handle is off and now I need to drill out the old stud and replace it somehow. Anyone know the correct replacement for that peened pin hinge shaft? If I can get the flapper side of the handle off, I think I could replace the stud with a nearly invisible repair. |
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| bbrock |
Jul 25 2017, 09:32 PM
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#16
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains
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Okay, after cutting the nut loose and getting my door handle off, I've run into a few other issues.
1. I discovered a hairline crack indicated by the red arrow below. It doesn't go all the way through yet, but it is probably only a matter of time. Could I take this to a shop and have it brazed for reinforcement? Seems like that would work. Or what would solder do? I could do that myself. I'm just not sure how much reinforcement it would provide. I would love to hear opinions.  2. Just replacing the ruined stud with a nut and bolt isn't going to cut it for me. I think it would be fairly easy to drill out the stud, countersink the hole, and solder or JB Weld a flathead bolt in place. After rechroming the part, it should be fairly invisible. But before I do that, I'm looking at options to more closely replicate the original. It looks like the stud is a self-clinching threaded stud sandwiched between the tab and the small metal reinforcement that appears to either be soldered or brazed to the tab. I can't tell because it is plated over. Anyone know? If it is soldered, it should be easy to remove and solder red locktite in a new stud. But it would be nice to know before applying any heat. 3. Finally, anyone know where to find a replacement for the hinge pin that is peened on both ends? Seems like it should be a common hardware part but I'm not even sure what it would be called. Closest I've found is a "headless rivet" and those don't seem easy to source. Alternatively, I'm guessing a rivet with low profile head would do. What have other people used? Thanks in advance for any tips and advice. |
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| 914Sixer |
Jul 26 2017, 06:32 AM
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#17
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914 Guru Group: Members Posts: 9,032 Joined: 17-January 05 From: San Angelo Texas Member No.: 3,457 Region Association: Southwest Region
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Just get another door handle. The crack it going to get you. These were made of pot metal, not repairable.
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| jeffdon |
Jul 26 2017, 08:42 AM
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#18
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Senior Member Group: Members Posts: 1,094 Joined: 24-October 06 From: oakland, ca Member No.: 7,087 Region Association: None |
QUOTE(URY914 @ Jul 10 2017, 07:59 PM) QUOTE(arne @ Jul 10 2017, 04:54 PM) I believe that someone here on World can repair these handles. That would be me. (IMG:style_emoticons/default/biggrin.gif) Cut off the stud/nut. Remove the handle. Drill the out stud. Replace the stud with a bolt or counter sink a screw. If (or when) you break the mounting tab off when doing this, send it to me and I'll replace the tab. How the hell are you mending the pot metal? |
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| URY914 |
Jul 26 2017, 05:12 PM
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#19
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I built the lightest 914 in the history of mankind. Group: Members Posts: 124,157 Joined: 3-February 03 From: Jacksonville, FL Member No.: 222 Region Association: None |
QUOTE(jeffdon @ Jul 26 2017, 07:42 AM) QUOTE(URY914 @ Jul 10 2017, 07:59 PM) QUOTE(arne @ Jul 10 2017, 04:54 PM) I believe that someone here on World can repair these handles. That would be me. (IMG:style_emoticons/default/biggrin.gif) Cut off the stud/nut. Remove the handle. Drill the out stud. Replace the stud with a bolt or counter sink a screw. If (or when) you break the mounting tab off when doing this, send it to me and I'll replace the tab. How the hell are you mending the pot metal? I'm not mending the pot metal. I'm replacing it with aluminum angle that replaces the bushing. Seeeeeeeee....  |
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| URY914 |
Jul 26 2017, 05:16 PM
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#20
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I built the lightest 914 in the history of mankind. Group: Members Posts: 124,157 Joined: 3-February 03 From: Jacksonville, FL Member No.: 222 Region Association: None |
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