Took the driver's door apart today to change the door glass channel. I already knew the door panel was a problem, and that something funky was up with the inner release handle. As far a I can see, the only rubber in the door is the glass guide & the rear molded seal, (front outer seal I've already done) which I have coming tomorrow. 

First problem was that the window crank was epoxied to the winder

Botch repairs here

Release plate is cracked & distorted. 

release rod for outer handle is also a problem. I'll weld the rod.

release plate straightened out - have to weld the stress crack & reinforce the plate

The spline section of the winder crank was buggered, so I cut it off & prepped a replacement spline section from a 240 (Volvo) window winder

drilled both pieces & used a roll pin to join the pieces before welding, which I will do tomorrow.

Volvo crank is screwed in place once attached, no more spring clip to worry about. Crank winder plate rivets were drilled out to remove winder.

 

Edited August 7, 20231 yr by HusseinHolland

OK. Got the outer handle release rod welded. I looked at using other rod as the threads were damaged at one end, but it's an odd ball size - seems to be 4.5mm .75 pitch. So, I flipped it & welded the damaged end to the main rod. Forgot to take a pic.

Welded the winder spline to the shaft & put the crank back together, applied new grease to the mechanism.

original splines

Welded the inner release plate, and added a tongue that hooks over the back of the retaining plate, so the leverage load is not unsupported

welded the cracks in the plate 

Before I put the door innards back in, I drilled the 3 new holes fore the all-metal chrome mirror I got from Zcardepot. I moved it as far forward as possible while still covering the existing holes. I considering welding them up, but that will have to be another day. Thunderstorms were coming in. I used M5 riv-nuts to score the mirror base, I hate sheet metal screws

after that I reinstalled the glass, winder & release

for the life of me, I can't figure out where these seals are supposed to go on the outer edge of the door frame. Anyone have a pic of one installed?

Still have to figure out if I can repair the door panel

Edited August 8, 20231 yr by HusseinHolland

That door panel is pretty rough!!

7 minutes ago, Patcon said:

That door panel is pretty rough!!

Yeah - I assume the monkeys that did the "repairs" to the mechanisms must have literally ripped it off the door.

The seals look like #1 in the top drawing.

2 hours ago, Freez74 said:

The seals look like #1 in the top drawing.

It is - but there is no obvious way to attach it, and since mine are gone I have no frame of reference

They are glued on before the door panel is installed, cover the open space between the window frame and door.

Thunderstorms on & off today, so not much time outside. I worked on repairing the door card as best possible for the time being. Going to get new door cards when they become available.

cardboard & gaffer's tape

removed the original rivets 

riveted in place, 3M super trim adhesive to re-bond the foam to the card

edges done last. 

Back in the car. Armrest is a brown one I painted, the original was f'kd.

Hard to photograph the damaged rear corner, the vinyl is all torn up here. They had duct taped the panel to the door skin  😞

2 hours ago, Freez74 said:

They are glued on before the door panel is installed, cover the open space between the window frame and door.

Lol - I should have looked at the thread before I put the panel back on 

 

Edited August 8, 20231 yr by HusseinHolland

I found that out the hard way, also.  I didn't want to take the door panel off after all that trouble.

Did the best you could with what you had to work with!! Kudos my friend 

Installed the passenger mirror today

Installed M5 rivnuts after this

mount plate installed, M5 machine screws

Much better!

 

Forgot to add the door glass rollers (ZcarDepot) went in - another thing I didn't know I was missing