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PointedThree :  Vans, Trucks, SUVs and Other Forums : G-Class DIY Forum : Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

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Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.
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Posted 4/15/2012 5:44 PM
G-AMG
G-Class DIY Host




Date registered: May 2006
Location: South Texas
Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350
1000
Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

I typically don't have a Potty-Mouth, but the design of the W463 Interior Door Opening Handles are CRAP, CRAP, CRAPPPPP!!!!!!!

This is the 3rd one to fail, for me, one done under warranty. What an absolutely IDIOTIC Design! The Flimsy ABS Plastic "Ribs" are under strain each time the Bowden Cable is Tensioned upon pulling the door handle... after a time, the Ribs FAIL. So, when you pull the handle, all it does is "Accordion" the ribs, rather than release the door.

I actually see this as a big SAFETY flaw. How are you supposed to get out in an Emergency??

Seeing that the cost is ca. $150 bucks, "Hell No!" Says, I.

I have used this method before, and I can't rave enough about the 3M Product 04247...

It is designed to repair plastic parts such as Bumper Mounting "Eyes"; for Repairing Plastic Parts, etc...

A Humungo Warning, though!! They are NOT kidding about "Super Fast" action. Once the material mixes, you have only a FEW SECONDS of working time!

Once the Bonding Material is in place... it's there for Good! It is Hard, but not "brittle".

Sooo, I have Buttressed the Original Design by Gluing a Thick piece of ABS plastic in between the two small "ridges" on the part.



If you have noticed, I have changed my Titles... In light of the words "Liability" used in a few Posts by some... it has made me "nervous". Therefore, I am titling my posts as "Do It 'Myself'", rather than "Yourself". My Posts are now intended as "Entertainment Value Only", and are not meant for use as Repair Guides. They are merely a pictorial of my experience, and nothing more. I deny any culpability if someone decides otherwise, and messes themselves, or their truck up.

G



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#202847
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Posted 4/15/2012 11:19 PM
hipine



Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
5000
RE: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

"... it also produces a lot of heat..."

Those kinds of chemical reactions are exciting, if maybe a little scary.

That sounds like good stuff. I just this afternoon finished re-repairing my passenger side map pocket. I used epoxy again, this time pressing in some wire mesh to reinforce it. The last repair held for 4 or 5 years. We'll see how this one goes. If it doesn't hold, I'll be looking for some of that exothermic wunder goo.

-Dave G.
#202855 - in reply to #202847
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Posted 4/15/2012 11:44 PM
AlanMcR
Expert




Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
2000
RE: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

What worked for me (on the map pockets) was a stainless washer backed up with fiberglass cloth, all embedded in epoxy.  I just did the broken ones.  I should have done them all on the first go. 



Edited by AlanMcR 4/16/2012 1:23 AM
#202858 - in reply to #202855
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Posted 4/16/2012 10:04 AM
nadd
Expert




Date registered: Apr 2006
Location: UAE, Dubai
Vehicle(s): G500 2016 LHD, numerous Chevys
Posts: 1285
1000
Re: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

Way to go with the DIMs as you can never be too careful, especially in the USA! But we do appreciate your adventures in opening up parts of your cars that some would shudder to touch :-)

Wonder if you can retrofit pre-2001 463 handles, we never had trouble with those, both in hot and cold climates.
#202883 - in reply to #202847
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Posted 4/16/2012 10:15 AM
tj4tj4
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Date registered: Jul 2009
Location: Das Hinterland, Wisconsin
Vehicle(s): G550 (2014); G55 (Europa 2000)
Posts: 277
100
Re: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

nadd - 4/16/2012 10:04 AM

Wonder if you can retrofit pre-2001 463 handles, we never had trouble with those, both in hot and cold climates.


I'm going to disagree with this one, I've already replaced the driver's side handle and the passenger-side just broke. POS upper clip made of plastic. I'll give that epoxy a try, most seem not to work on auto plastic.
#202885 - in reply to #202883
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Posted 4/16/2012 4:10 PM
nadd
Expert




Date registered: Apr 2006
Location: UAE, Dubai
Vehicle(s): G500 2016 LHD, numerous Chevys
Posts: 1285
1000
Re: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

tj4tj4 - 4/16/2012 3:15 PM

nadd - 4/16/2012 10:04 AM

Wonder if you can retrofit pre-2001 463 handles, we never had trouble with those, both in hot and cold climates.


I'm going to disagree with this one, I've already replaced the driver's side handle and the passenger-side just broke. POS upper clip made of plastic. I'll give that epoxy a try, most seem not to work on auto plastic.


We must be lucky then, or perhaps you hit a bad batch, like the upper arm rest tab that keeps breaking (in grey), and the mirror bases that keep rusting, on some but not all.
#202895 - in reply to #202885
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Posted 4/16/2012 7:13 PM
fernweh



Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
2000
Re: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

I found some really "hot" stuff to repair things like the door handle.

It is called Q-bond.

2-part stuff, it comes with a small bottle of black and gray powder each, and another two bottle of catalysts.

You pour the powder around the broken, damaged or failed part and drop some of the catalyst onto the powder.

If Rube thought he had some fast epoxy - this is super fast.......and smokes a bit, it is real hot and strong.

Perfect for repairs and reinforcements.

I purchased this box at my indie parts guy.....

Karl



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#202899 - in reply to #202895
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Posted 5/21/2014 10:09 AM
MudMonkey
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Date registered: Jun 2013
Location: CO
Vehicle(s): '03 G500
Posts: 274
100
Re: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

Great DIM!

Just to be certain... you performed the repairs using ABS plastic? About how thick was it?

Edited by MudMonkey 5/21/2014 10:13 AM
#221993 - in reply to #202847
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Posted 7/1/2014 5:12 PM
MudMonkey
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Date registered: Jun 2013
Location: CO
Vehicle(s): '03 G500
Posts: 274
100
Re: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

My G has just developed a very annoying habit... the small steel hook at the end of the cable that attaches to the door handle refuses to stay hooked into that door handle.

The hook jumps out of the handle... of course, it waits 'til I have re-installed the door handle assembly... then the next time I pull the handle, the door will un-latch, and then the hook will then jump out of the door handle.

Is there some sort of plastic/metal stay that is supposed to hold the hook tightly in place? I would think the hook would do the job on its own, but it manages to find its way out. It happened four times today in less than two hours. I'm going to have to keep a screwdriver in the center console until I can get this figured out, so that I can re-connect the cable to handle, to get out of the truck.

Yeah, annoying...
#222698 - in reply to #202847
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Posted 7/1/2014 9:38 PM
MudMonkey
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Date registered: Jun 2013
Location: CO
Vehicle(s): '03 G500
Posts: 274
100
Re: Photo DI'M'- Rube Goldberg repair of Lousy W463 Interior Door Handles.

Ok, figured it out. The cable was not putting enough tension on the hook to keep it tight - the cable's routing was not correct further back in the door panel, maybe from when it had the window regulator replaced by the previous owner. Now the cable is nice and tight, so this last time, it was a bitch to get the hook into the door handle - so little slack. The door handle feels great now.
#222705 - in reply to #222698
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