Interior Door Panel Repair Thread

bbade · 07-02-2010, 02:24 PM

**Full-size pictures available by clicking on the thumbnails**

Repairing broken studs. Here is the culprit:
DSCF4040.jpg

You will need a nylon bushing (3/8" OD, 1/2" length, ID less than 9/32") found at your local hardware store.
OD - outer diameter
ID - inner diameter
You will also need some Plast-Aid, more about that in the next post.

Step 1: Drill the nylon bushing to 9/32" ID. This will fit nicely over the broken stud.
DSCF4041.jpg

Step 2: We want to cut two slits in the nylon bushing so that it will fit down on the stud around the four existing plastic reinforcement tabs as shown in the following picture.
DSCF4044.jpg
To do this use a dremel tool with cutoff wheel attached. Cut the slits to a depth of 1/4," this will leave 1/4" above the plastic reinforcement tabs and make it flush with the foam on the back of the door panel when finally mounted.
DSCF4043.jpg

Step 3: Enlarge the mounting hole for the stud in the door panel to 3/8" using a 3/8" drill bit.
DSCF4046.jpg

Instructions continued in the next post.

07-02-2010, 02:24 PM	#2
bbade Rotary Fanatic Join Date: Mar 2008 Location: Macungie, PA Posts: 163 Rep Power: 18	Broken Stud Repair Full-size pictures available by clicking on the thumbnails Repairing broken studs. Here is the culprit: DSCF4040.jpg You will need a nylon bushing (3/8" OD, 1/2" length, ID less than 9/32") found at your local hardware store. OD - outer diameter ID - inner diameter You will also need some Plast-Aid, more about that in the next post. Step 1: Drill the nylon bushing to 9/32" ID. This will fit nicely over the broken stud. DSCF4041.jpg Step 2: We want to cut two slits in the nylon bushing so that it will fit down on the stud around the four existing plastic reinforcement tabs as shown in the following picture. DSCF4044.jpg To do this use a dremel tool with cutoff wheel attached. Cut the slits to a depth of 1/4," this will leave 1/4" above the plastic reinforcement tabs and make it flush with the foam on the back of the door panel when finally mounted. DSCF4043.jpg Step 3: Enlarge the mounting hole for the stud in the door panel to 3/8" using a 3/8" drill bit. DSCF4046.jpg Instructions continued in the next post. __________________ Proud owner of a base 1993 Montego Blue FD. PFC, RB single tip, Koyo Radiator, KDR rebuilt motor, polished OEM front strut bar, FEED replica sideskirts, OEM 99 spec rear spoiler, SuperPro Bushings Many thanks to Dave at KDR for sparking my rotor addiction. Last edited by bbade; 07-02-2010 at 02:47 PM.