Broken door panel plastic repair tips needed
#16
Lots of great solutions here. Unfortunately, I didn't see this post until I repaired mine. I used an approach I employed to fix a broken plastic headlight bracket on my Audi - it's held up for over 15 years.
I don't have any before pictures, but like most I'm sure, 5 of the 6 mounting points were cracked, missing pieces and even missing altogether. On mine, what remained was dimpled towards the back from the screw/washer.
I used .025" aluminum sheet (Lowes) to form (using a hand shear & electrician's pliers) backing plates. I bonded/clamped the backing plates using a liberal layer of 5 minute epoxy. The dimples were made by using 2 sockets (OD of smaller socket fits into ID of larger socket) clamped in a vice with the aluminum in between. For the completely missing tab (3rd pic) I folded over the aluminum to double its thickness. It's very solid now - just need to drill the holes.
There is no evidence that my RS door panel was ever apart - when I take it apart, I plan on doing this whether it needs it or not.
I don't have any before pictures, but like most I'm sure, 5 of the 6 mounting points were cracked, missing pieces and even missing altogether. On mine, what remained was dimpled towards the back from the screw/washer.
I used .025" aluminum sheet (Lowes) to form (using a hand shear & electrician's pliers) backing plates. I bonded/clamped the backing plates using a liberal layer of 5 minute epoxy. The dimples were made by using 2 sockets (OD of smaller socket fits into ID of larger socket) clamped in a vice with the aluminum in between. For the completely missing tab (3rd pic) I folded over the aluminum to double its thickness. It's very solid now - just need to drill the holes.
There is no evidence that my RS door panel was ever apart - when I take it apart, I plan on doing this whether it needs it or not.
#17
Rennlist Member
I used the original metal braces 10+ years ago - developed by Peter Clark here in Oz originally - never another problem with door handles etc. Not sure if there is a connection with Rob Budd's product, but Peter did sell some to 928 International..
jp 83 Euro S AT 57k
jp 83 Euro S AT 57k
Last edited by jpitman2; 09-26-2018 at 05:07 AM.