Interior Door Panel Repair Thread

bbade · 07-02-2010, 02:31 PM

Step 4: Test fit the plastic piece to ensure proper fitment and alignment. Make sure that the nylon bushing is flush with the back of the door panel and make sure that the plastic piece lines up correctly.
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Plast-Aid http://www.plast-aid.com/
Credit goes to 'nashman69g' on 7club for experimenting with this stuff, it is actually how I found it. Some great information and tips on using it can be found in this thread on 7club http://www.rx7club.com/showthread.ph...plastic+repair.
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Step 5: Clean the nylon bushing and broken stud with acetone. Be cautious with the acetone as it can soften/melt the plastic if left to sit on the plastic. I put some acetone on a rag and wiped everything down, allow it to evaporate.

Step 6: Put some Plast-Aid on the inside of the nylon bushing and then press it down on the broken stud. Fill the nylon bushing with Plast-Aid, bringing it level with the top of the bushing. Liberally spread Plast-Aid around the bottom of the nylon bushing (the area with the slits) to bond it with the plastic reinforcement tabs. Avoid getting Plast-Aid on the outer area of the bushing that will go through the hole in the door panel so that you don't need to trim it down later.
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Allow the Plast-Aid to set up, it should not take long at all. The stud should now be ready to drill and tap, I will post information on this step when I get to it, I may upgrade the fasteners in the process.

07-02-2010, 02:31 PM	#3
bbade Rotary Fanatic Join Date: Mar 2008 Location: Macungie, PA Posts: 163 Rep Power: 18	Broken Stud Repair Step 4: Test fit the plastic piece to ensure proper fitment and alignment. Make sure that the nylon bushing is flush with the back of the door panel and make sure that the plastic piece lines up correctly. DSCF4047.jpg DSCF4048.jpg Plast-Aid http://www.plast-aid.com/ Credit goes to 'nashman69g' on 7club for experimenting with this stuff, it is actually how I found it. Some great information and tips on using it can be found in this thread on 7club http://www.rx7club.com/showthread.ph...plastic+repair. DSCF4050.jpg Step 5: Clean the nylon bushing and broken stud with acetone. Be cautious with the acetone as it can soften/melt the plastic if left to sit on the plastic. I put some acetone on a rag and wiped everything down, allow it to evaporate. Step 6: Put some Plast-Aid on the inside of the nylon bushing and then press it down on the broken stud. Fill the nylon bushing with Plast-Aid, bringing it level with the top of the bushing. Liberally spread Plast-Aid around the bottom of the nylon bushing (the area with the slits) to bond it with the plastic reinforcement tabs. Avoid getting Plast-Aid on the outer area of the bushing that will go through the hole in the door panel so that you don't need to trim it down later. DSCF4052.jpg DSCF4053.jpg Allow the Plast-Aid to set up, it should not take long at all. The stud should now be ready to drill and tap, I will post information on this step when I get to it, I may upgrade the fasteners in the process. __________________ 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 02:52 PM.