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I cut 1/4" ABS to dimension and cut a shoulder in it to fit the zig in the ABS of the door pocket where it is screwed in behind to the rear of the door handle
I bet a little plumbing ABS cement could be used to fuse the new plate to the old wall of the pocket. A DIY home store item. Andy
I just finished doing this on my car. I used a bench grinder to SLOWLY grind down the shoulder part of the plastic and while it didn't work our quite as neatly as for the OP it's still much better than before.
I did have to use a longer screw and also forgot to [re drill the pilot hole before I glued the plate in place. To get around that thought I just took a long framing nail of approximately the same width as the screw and heated up with a blow torch. Once it got nice and hot I just poked it through the plastic using the old hole as a guide. It went through like butter.
I did this four years ago on the C2 and just finished up the same repair on the C2S.
I bought a 4" ABS slip cap from the local plumbing store for about $6 and started cutting away. One slip cap will do for both sides and is about 1/4" thick.
I used JB-Weld again, as it is a perfect epoxy to shape, sand and paint.
Drilling the holes can be a bit tricky but with the 90° attachment on my dremel tool I was able to get in there perpendicular to the surface, but because of the limit on the size of the drill bit, had to grind it out a bit to allow for the screw to go trough freely. Longer screws are required.
Sand the surface once more, mask with tape and paper, then a couple of coats of the Semi-Gloss rattle can and done!
I just JB Welded a piece of spring steel from a large binder clip onto the original plastic. JB Weld all over the place (fully covering the thin steel) then sand it down and clean up. Looks basically new and can be done with minimal tools in about 15 min.
Time for me to move these out to fellow rennlisters.
I have 9 extra sets of door pocket reinforcement pieces. Each set will repair 2 door pockets. You may need to do some shaping. See my previous posts to this thread for how to install these.
Not sure what the response will be so here are my requirements.
Reply to this thread if you are interested. Then follow up with a PM to me with your name and postal address.
I will mail these out within the continental US for free. If you are outside the US or off-continent and are interested, I may ask you to cover postal/shipping fees.
05-24-2015, 12:35 PM
