Repair of Door Bins

87-911 · 04-09-2002, 07:24 PM

The plastic of the door bins has cracked in the area where they fasten to the armrest/grab handle on my 87. I suggestions for the best type of adhesive/cement to "weld" the carcks and add a re-enforcing plate. I am not sure of the plastic type used for the "Z" shaped piece. Thanks in advance!

Don Plumley · Don Plumley's Garage

If I understand where yours is cracked, mine was too and glue won't do it. I made a metal bracket, pop-riveted it to the plastic.

Let me run into the garage and get a pic for you. Standby...

Don

87-911 · 04-09-2002, 08:41 PM

That's what I wanted to do - but use a bracket and adhesive. Look forward to seeing the graphic. Thanks

Don Plumley · Don Plumley's Garage

Here's a pic of the aforementioned bracket:

If I recall, after the drilled the holes for the pop-rivets, I used a standard quick-setting hobby cement (like for plastic (styrene) models) in the crack, then riveted the bracket to the pocket. You could use any five minute epoxy to fasten the bracket to the plastic, but I doubt if it would last (plastic is not to grippy). Good excuse to get a pop-rivet gun if you ask me.

If it's not clear, the pocket is fixed whilst out of the car, there is a third hole which the screw attaches the bracket (and hence the pocket) to the door grab handle.

Drop me a note if you have any questions.

Don

87-911 · 04-09-2002, 08:48 PM

Thanks Don = Mine is more severely damaged and need the bracket to re-enforce the area under the door release also - but that's the approach I envisioned.

Nice craftmanship!

Can you bend the pocket covers back in shape? - is there a metal stay embedded in the foam?

Don Plumley · Don Plumley's Garage

The resolution on the pic does not show the full crack - needless to say it was fully separated and someone just put a huge washer on it trying to hold it together.

If you need to reinforce under the door pull, you could do this in the same way with a bit of sheet stock. Sounds like a job for serious epoxy, maybe some marine stuff. Find a way to really clean the plastic first.

As for the pocket covers - do you mean the lids or the pockets themselves?

Chris Lovell · 06-10-2002, 07:02 PM

The problem I would like some help with is where the wall of the door pocket is stretched toward the driver/passenger so the pocket cover no longer rests on the pocket wall. And being a perfect elbow rest, this cover gets further pushed into the pocket. I wondered if I could heat the carpeted side wall and reform. Or place forming ribs inside. Or something equally creative.
Thanks.

BTW, I did Don's identical repair a few years ago. Makes good sense and works.

Superman · 06-10-2002, 09:23 PM

I've thought about the sagging pockets too. I believe they are made out of really herky cardboard. German cardboard if you will. I am likely to cut a piece of lumber the correct length, close the doors so that the lumber is pushing the pockets back into shape, and then spray the pockets with water. Let dry. Voila.

Todd Simpson · 06-11-2002, 08:23 AM

That repair looks great. I did the same with 2 zip ties crossing the crack and JB Weld epoxy. Not as pretty but very strong.

Todd

Chris Lovell · 06-12-2002, 07:54 AM

S-man,
Cardboard, eh. Like some tough pressboard or something? Let me know when you try to "soak and shape" method.
Thanks,
CL

Noel · 06-12-2002, 11:29 AM

I just fixed cracks in mine with some JB Weld. It is available at any Autozone/Pep Boys. It comes in two tubes. Simply mix it up and apply with an old spoon and in several minutes and it turns into very hard plastic. I fixed a small crack in my airbox with it and a friend of mine fixed his radiator at the track with it and continued to run several 25 minute sessions.

Noel

Paul Valcourt · 06-12-2002, 11:47 AM

If you are looking for a really good adheasive for bonding try quick dry urethane (used for installing winshields). It is verrry messy to work with but sticks to just about any cleaned surface and remains a little flexible. It takes about 24 Hrs. to set-up, after that you will not pull the pieces apart. You just have to make sure you have some automotive paint thinner or gun wash to clean up any excess or smears.