Interior Door Panel Repair Thread

[bbade]

Originally Posted by bbade

This third fix will work as I am done playing around . I have ordered ABS rod from McMaster Carr and am going to make one heck of a robust stud. I will outline the process and post it here sometime next week.

My apologies for never finishing the write up. I logged in today for the first time in months (years?). The FD is currently sitting on jack stands in the garage awaiting a new coat of paint in the engine bay. Anyway, back to the write-up. I don't have detailed instructions as it has been quite some time since I finished this project; however, here goes.

The ABS rod worked out very well. Using a lathe I machined the rod down to the diameter of the original stud or just a bit thicker. I left a nice base at the bottom for ease of bonding.
DSCF4140.jpg
Make sure you cleanup the bonding area (you can see the nylon attempt mentioned earlier).
DSCF4139.jpg
Put some Plast-Aid under the post, then reinstall the plastic piece in the door panel to line everything up. After this initial bond sets up reinforce with additional Plast-Aid.
DSCF4144.jpg

In summary I am more than happy with the result. Hope this helps, happy new year!