Help w/ replacing Door Handle Pin

[tysamigo]

I have removed both door handles completely. Now I need to separate the actual HANDLE from the assembly. There is a PIN that holds them together. I need to drill out the pin and then later replace it. However, I can't find a replacement. I've tried Merlin, the guy who painted my VX and his crew, 2 of the largest and oldest local body shops (open since 1940-1950's), the guys at Fastenal, and Louisville Fasteners and ALL with no luck.

I've been told I would have to have something fabricated or use an ALL THREAD which basically looks like a long skinny bolt but is threaded the entire length and then to have 2 nuts on each end.

This is the only idea so far.

Any suggestions???????

[Cobrajet]

I would think that you could find some kind of rod (or nail) that diameter and length at a hardware store. Flush valve rod... toy car axle...

Think outside the box.

[bartmanS4]

Are you sure you have to drill the pin out? Could it be pressed out and reused?

[tysamigo]

Are you sure you have to drill the pin out? Could it be pressed out and reused?

That was my first thought, but 2 of the guys (both of them own presses) said that it's unlikely it would make it without damaging the end of the pin OR the plastic handle itself if they were to try and remove it by pressing it out...

[tom4bren]

It looks like it is actually a piece of tubing that has been flared at each end.

You can pick up a flaring tool at Harbor Freight (or I can loan you mine) & you'll just have to find the right sized tube at your local hardware store (or plumbing or air conditioning supply store).

It shouldn't be too complicated & you can practice on a scrap piece before you get started so you can make sure it'll work out for you.

The flaring tool will just spread out the diameter of the tube so that it won't go back through the hole. If you want to actually curl the edge of the tube over (like shown in the picture), you can pick up a cheapo snap repair kit at Lowes that has a punch like thinggy that you hammer onto the end causing that curling effect (I have one of those too if you need to borrow it).

[tysamigo]

It looks like it is actually a piece of tubing that has been flared at each end.

It's actually a pin, and a VERY hard and durable pin at that. Merlin confirmed it's a pin and that a Pin/Spring Kit was once available from a 3rd party but they are no longer in business and he has no idea where to search. It's just like a pin that you would have in the door hinges in your home but much smaller. It's surprisingly sturdy. I'm guessing because of all the pressure it has to endure from the force of the spring.

2 different guys at body shops today made a comment that they've not seen metal pins in door handles before. They said all the door handles they see are pretty much plastic. They kept asking "uh... what did you say they came out of" lol

I'm still clueless as to what to do... but I won't quit. I HAVE to do this project. It's the only thing holding me up right now

[tom4bren]

It's actually a pin, and a VERY hard and durable pin at that.

I believe you that it is hard & strong ... but I see a hole in the center of the "pin". Where I come from, a hollow pin is a "tube".

OK, since you've so effectively POO-POO'd my idea, here's another:

You only need to grind off the curl on one end, & then you should be able to drive the pin out. Now take the pin & tap some threads into the hole. Next take a hack-saw & make a cut lengthwise about 1/2" deep into the threaded end. Run the tap into it again to make sure you didn't goober up the threads. When you are ready to re-assemble, drive the pin in & secure with a panhead screw of the proper size, thread, & length. The screw will expand the end of the pin and secure it in the plastic hinge. You can crimp down the end of the pin a little to make sure it doesn't hang up when you are putting it back in since the screw will be forcing it back apart.

I can try to draw a picture of what I'm talking about if that'd help.

[tom4bren]

I'm not much of a draftsman but this is what I was thinking.

Why are you taking it apart anyway? If it's for a repair, you can probably source replacements from a boneyard. If it's for some kind of modification ... then understandable.