door panel removal 1987 door handle paint

[Dublinoh]

My 1987 Carrera had a pretty tired looking door handle so I decided to remove it and paint it, new ones are $300+. It looked like this:



First disconnect the battery:



Next step was to remove the top piece of the door panel:
remove the two screws on each end then the last two screws that hold it to the door







Next unplug the the mirror adjustment wires, there are two areas to release one on top one on the bottom:

[Dublinoh]

Then the four bolts on the inside handle:




To reach the lower ones release the door handle from the metal rod, just lift up on the rod and it pops out:



Now remove the lower pocket which is held on by six screws, not hard to find these:





Now the screw at the end of the flap on top of the pocket:



release the door locking knob by removing the screw and then turn the larger trim circle to unscrew it I used a trim tool:





this helps the next amateur.

[Dublinoh]

Then you can begin to release the snaps:



At this point I was able to release the door panel and drop it down several inches, because I only wanted to remove the door handle I decided to not disconnect the window switches and speaker.





I didn't want the handle to fall so I taped it to the door:



The nuts that hold on the door knob are difficult to reach, they are 8mm, this is how I got them off:




One washer was just hanging and I couldn't get my fingers around it so I used duct tape:



So finally the handle is off and looks like this:




My plan is to sand and generally clean this up and then paint is black again. So I will add to this post when I get ready to reinstall.

[Rob G]

Great write up. I'm looking forward to the finish.

[Bob Kontak]

Originally Posted by rob g

great write up.

+1

Where did you get the blue tool?

[Dublinoh]

"5pc Panel Removal Set" Sold by our host:

Porsche 911 & Carrera Panels & Doors - Page 7

[ShakinJoe]

Nice write up. They also polish up nice if that look does it for you.

[Dublinoh]

Now that the handle is off I wanted to remove the lock so I wouldn't scratch it/paint it etc.

First remove the screw at the top:




Then remove the clip from the side of the handle, this comes off very easily:




Then just slide the lock out of the handle it looks like this:



Then I sanded off the old paint with 150 sandpaper, my paint came off easily. I used foil and tape to mask off the handle. So now primer and the black paint. I have black semigloss rust-oleum. If you have a better suggestion for paint let me know I'll buy the primer tomorrow. I'll post again after paint.

[Dublinoh]

Originally Posted by ShakinJoe

Nice write up. They also polish up nice if that look does it for you.

Passenger side looks good so I think I'll paint and avoid opening other side.

Thanks for the kind remarks all.

[timmy2]

Sand and paint the trigger too. You'll look at it and curse every time you open the door if you don't!

[Dublinoh]

Originally Posted by timmy2

Sand and paint the trigger too. You'll look at it and curse every time you open the door if you don't!

Yes...good call, thanks

[Dublinoh]

So after sanding with 150 I applied two coats of primer with very slight sanding between coats (400 paper):





after 24 hours two coats of semi gloss black Rust-oleum (about 45 min between coats) and then let it cure for 24 hours



some light cleaning of the other parts and some lithium grease between moving parts. Finally some graphite on the lock and ready to install. Used some tape to stabilize again but avoided tape on newly painted areas.



It was a little frustrating trying to get the door handle nuts started, I glued the washers to the nuts and after 15 minutes or so got them started. The rest of the install was the reverse of removal as they say.

Pictures of the finished before and after:

[timmy2]

Great job, looks almost new and very nice write up.

[mschwien]

Getting ready to do this myself - I had heard that before you take the lock cylinder out of the handle you should insert your key so the pins do not fly out - but that does not seem to be the case?

Nice job on the pics and process!

Thanks!
Mike

[Dublinoh]

Originally Posted by mschwien

Getting ready to do this myself - I had heard that before you take the lock cylinder out of the handle you should insert your key so the pins do not fly out - but that does not seem to be the case?

Nice job on the pics and process!

Thanks!
Mike

Didn't happen to me but you could easily insert the key. This really was pretty easy, only the nuts on the handle are awkward...and would be easier if you removed the door panel completely. Good luck with it.

[88911coupe]

I think the orig finish is anodized, mine looks very faded, this looks like a fun project for a Saturday. Any special paint that can take the constant handling?

[Dublinoh]

Originally Posted by 88911coupe

I think the orig finish is anodized, mine looks very faded, this looks like a fun project for a Saturday. Any special paint that can take the constant handling?

I think someone had painted mine before. I used Rust-oleum products in the can...sanded 150, 2 coats primer, 2 coats semi gloss black. For all steps; takes a couple days for the paint to cure. It seems like a durable surface but time will tell. Need to hit the key hole with the key especially. Good luck with it

[Nine9six]

Originally Posted by Bob Kontak

+1

Where did you get the blue tool?

Those same tools can be had at Harbor Freight for less than 1/2 the price.

[88911coupe]

Maybe powdercoat is an option?

[twistoffat]

Originally Posted by Dublinoh

Then you can begin to release the snaps:








My plan is to sand and generally clean this up and then paint is black again. So I will add to this post when I get ready to reinstall.

Does anyone have a part number of the screw visible on the back of this handle .its the one that keeps the lock barrel in place.?