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FC3S Door Handle Upgrade
01-24-12, 11:13 AM
#51
as far as i'm concerned, pot metal is weaker than most aluminum alloys for tensile strength. that is not from research but from real world experience seeing pot metal break on tools and random items.
the FD guys are casting many parts from aluminum now, including door handles.
i'd actually wager that many items you get from china with that dull grey cast look are pot metal and not aluminum, reminding me of that thread about the chinese steering wheel adapters.
https://www.rx7club.com/2nd-generation-specific-1986-1992-17/fyi-ebay-steering-wheel-hubs-980640/
the FD guys are casting many parts from aluminum now, including door handles.
i'd actually wager that many items you get from china with that dull grey cast look are pot metal and not aluminum, reminding me of that thread about the chinese steering wheel adapters.
https://www.rx7club.com/2nd-generation-specific-1986-1992-17/fyi-ebay-steering-wheel-hubs-980640/
Last edited by RotaryEvolution; 01-24-12 at 11:16 AM.
01-24-12, 11:42 AM
#52
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just make a sand casting of it with thicker arms, fill casting with aluminum. trim and refinish the part. done.
forget the stainless steel route. it will be infinitely more expensive in every respect.
this is even a project that most could do at home with a little ingenuity. but if you burn your house down or melt your foot off don't come trying to blame me! hehe. youtube has plenty of instructionals on how to form castings and aluminum is about the easiest metallic material to work with.
yeah it won't be as strong as stainless but if you make appropriate adjustments it should be stronger than OEM.
if what you plan on doing is just making better legs and welding them to the original handle.. think again, it won't work regardless of what that guy told you. at best you could drill through the handle and tap the legs to have flush mount screws.
forget the stainless steel route. it will be infinitely more expensive in every respect.
this is even a project that most could do at home with a little ingenuity. but if you burn your house down or melt your foot off don't come trying to blame me! hehe. youtube has plenty of instructionals on how to form castings and aluminum is about the easiest metallic material to work with.
yeah it won't be as strong as stainless but if you make appropriate adjustments it should be stronger than OEM.
if what you plan on doing is just making better legs and welding them to the original handle.. think again, it won't work regardless of what that guy told you. at best you could drill through the handle and tap the legs to have flush mount screws.
And that stuff with the fire scares me. LMAO
01-24-12, 12:00 PM
#53
cnc stainless?
yeah.. i don't think you're going to get too many bites on them when they will be costing $350 per handle, regardless of how cheap the guy told you he could make them.. which is also probably why he's giving you the runaround now after he finally figured it out.
if you get 10 people who claim to be interested figure maybe 1 person will actually follow through and purchase.
yeah.. i don't think you're going to get too many bites on them when they will be costing $350 per handle, regardless of how cheap the guy told you he could make them.. which is also probably why he's giving you the runaround now after he finally figured it out.
if you get 10 people who claim to be interested figure maybe 1 person will actually follow through and purchase.
Last edited by RotaryEvolution; 01-24-12 at 12:02 PM.
01-24-12, 04:58 PM
#55
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Update
At first it was considered to be CNC stainless for the Handle part only and a welder was to just make the legs and weld them on.Seeing that some shops dont want to embark on such a small tedious and time consuming job..
One of the members mentioned sand casting.. Well as of today the handles are at a casting place..... they are going to give me the tooling estimates tomorrow
They might either be made in aluminum or another alloy stronger than aluminum.
Ill keep you guys updated.!
One of the members mentioned sand casting.. Well as of today the handles are at a casting place..... they are going to give me the tooling estimates tomorrow
They might either be made in aluminum or another alloy stronger than aluminum.
Ill keep you guys updated.!
01-24-12, 10:54 PM
#57
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The guy at the casting place was pretty cool. The business has been there over 50yrs. So tomorrow i will get the tooling pattern price.
01-25-12, 12:33 AM
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The handle will be casted.. It is up to the end user to cut his out and replace them with the new one....
01-26-12, 12:34 PM
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01-26-12, 12:47 PM
#62
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Update
Well today i will go and do the final talks with the guy. They are going to make a pattern for me for casting in either Aluminum or Zinc Aluminum..it all will come down to whats best as far as pricing goes.
In no way will i sell until i contact the site Moderators. This i make clear right now.
The part getting cast will be the DRIVER SIDE. I am trying to do this on a budget ; because that stuff will get expensive fast.
10 handles will be cast for the first batch. In the meantime ill be doing some research to find good pin and retaining ring combination for it.
I will soon discuss pricing with you guys.
Thanks
ROn
In no way will i sell until i contact the site Moderators. This i make clear right now.
The part getting cast will be the DRIVER SIDE. I am trying to do this on a budget ; because that stuff will get expensive fast.
10 handles will be cast for the first batch. In the meantime ill be doing some research to find good pin and retaining ring combination for it.
I will soon discuss pricing with you guys.
Thanks
ROn
01-30-12, 03:46 PM
#67
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PLEASE READ Update for Jan26
Good news.. I went ahead and did a deposit for the tooling of the pattern to be made....They are going to try and push it for me because they have a bit of work ahead of mine. It being a small part . The tooling price is not cheap at all.
But its a risk i am willing to take. I want it done the right way.
Waiting period is 1-2 weeks. For the tooling to be done and for me to get the first cast piece which i will test.. And trust me i am gonna be savage with it.
As of now i just have to find a good pin and e-clip for the kit.
Granted all goes correctly i will pay the according fees for the rx7 club vendors. And then proceed to do a group buy.
1:The first initial batch will be 10 but if the demand is high on it i can do 20 instead. Reason for this; its just me. I work a 8-5 and i want to keep track of things and be organized rather than overburdened.
2:Based on how well i do initially. And that manage to make up the cost of the pattern. I will jump ahead and do another pattern. I might experiment and do short runs of particular parts.And see how the demand is.
3:Later on i will see what is able to be done and not. Probably do voting on what part you guys would like to have made.
4: Spread the word. In the long run everyone will benefit from this.
But its a risk i am willing to take. I want it done the right way.
Waiting period is 1-2 weeks. For the tooling to be done and for me to get the first cast piece which i will test.. And trust me i am gonna be savage with it.
As of now i just have to find a good pin and e-clip for the kit.
Granted all goes correctly i will pay the according fees for the rx7 club vendors. And then proceed to do a group buy.
1:The first initial batch will be 10 but if the demand is high on it i can do 20 instead. Reason for this; its just me. I work a 8-5 and i want to keep track of things and be organized rather than overburdened.
2:Based on how well i do initially. And that manage to make up the cost of the pattern. I will jump ahead and do another pattern. I might experiment and do short runs of particular parts.And see how the demand is.
3:Later on i will see what is able to be done and not. Probably do voting on what part you guys would like to have made.
4: Spread the word. In the long run everyone will benefit from this.
01-30-12, 06:35 PM
#68
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has anyone tryed shaved door handles? i am wondering how they would work and if it would be better and cheaper than buying new handles? currently both of mine are broke 
01-30-12, 07:13 PM
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Shaved handles hehe. What it cost on materials,paint, electrical work. buying actuators etc. It will add up.
Ps... Both of mine are broke too.
Take sight at why i am putting effort into this!
01-30-12, 11:18 PM
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01-31-12, 12:59 PM
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01-31-12, 09:35 PM
#73
Although I would eventually like both the warning light surround and the A-pillar trim, my broken warning light surround is annoying me more, so I voted to see it first.
Future idea (if you need anymore
) my drivers side inner handle broke on one of my S5s so now I have to drop the window to let myself out from the outside handle. If its easy enough to make a metal replacement of that (currently aged plastic), that would be handy.
Future idea (if you need anymore
) my drivers side inner handle broke on one of my S5s so now I have to drop the window to let myself out from the outside handle. If its easy enough to make a metal replacement of that (currently aged plastic), that would be handy.
01-31-12, 10:28 PM
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Ideas
Although I would eventually like both the warning light surround and the A-pillar trim, my broken warning light surround is annoying me more, so I voted to see it first.
Future idea (if you need anymore ) my drivers side inner handle broke on one of my S5s so now I have to drop the window to let myself out from the outside handle. If its easy enough to make a metal replacement of that (currently aged plastic), that would be handy.
Future idea (if you need anymore
) my drivers side inner handle broke on one of my S5s so now I have to drop the window to let myself out from the outside handle. If its easy enough to make a metal replacement of that (currently aged plastic), that would be handy.Man an aluminum warning light trim would be sweet if it can be done
