RS door handle: Maybe a better way?

[carmaneddy]

I just finished installing the RS door panel on my '72 911S and one of the "Jack" nuts broke, so I had to come up with an alternative. Considering the stress this will be under from repeated use of closing the door. I think I have a better way


For about $4 at Lowes I bought a 3 ft length of aluminum stock; cut off a 2 inch piece and tapped it to recieve the screws for the RS handle. Next, I drilled a separate hole to rivet the aluminum piece in place.



You can see the Jack nut for the forward screw. I broke the second one thats why the modification, However, I think this is going to last longer and be stronger so I will do both screws this way on the driver side. And since the attachment stock is aluminum it is in keeping with the RS lightweight concept.



A picture of the finished door. I have to clean the silicone from the edge, Any suggestions?





A gratuitous picture of my car. As you can see it is but another RS replica. Body work and rust excocism by Tom Walsh at Stoddard Imports. He worked hard to get those 9 inch rears under the steel flares.

[Porschekid962]

silicone huh? i used 3M yellow weather sealant, its pretty neat in that the set up time is long enough to let you play with the water barrier so it fits just right and you can rub it off with your finger just like rubber cement. as for cleaning silicone i would suggest a razor blade. nice work on the car and keep it up.

[rpiper]

Looks great. Can we have more gratuitous pictures? It is still winter up here after all.....

[TRE Cup]

good job on the aluminum threaded strips. the original RS has welded in place threaded inserts. Another suggestion would be to weld the nuts to some thin washers, drill a hole that is large enough to let the welded nut go into the door cavity, then weld the washer to the door shell. both methods achieve the same end: secure mounting for the flimsy plastic handles

nice car!